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Specifications for SMC and TSMC Mk4, S-L-E


The SMC/TSMC-type piston compressor can be fitted with a range of equipment, depending on the function and requirements it is expected to meet. Some of these variants are discussed in this instruction manual, even if they are not featured on your particular unit. The variants featured on the unit are marked with an 'x' in the following diagram, with the compressor number stated below.

Compressor type

SMC

104

TSMC 106

108
S

E 112 116

Designation Compressor no. Refrigerant Control R717 Other _________

01 introduction.fm

UNISAB II Control- and regulating system Electro Mechanical System

Compressor cooling

Thermopump Water cooled top and side covers Air cooled top and side covers Oil cooling Oil cooling (water-cooled side covers) OSSI/OOKH

Drive type

Coupling V-belts

Explosion-proof electrical design Equipment for parallel operation SABROE OVUR-type oil separator

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1. Introduction

1. Introduction
The purpose of this manual is to provide the operating personnel with a thorough knowledge of the compressor as well information about: The function and maintenance of each component. Service schedules. curring during the warranty period where this is attributable to incorrect operation. YORK Refrigeration's manual concept covers six standard manuals: Engineering, Operating, Service, Installation and Commissioning, Transport and Spare Parts. Therefore, references may be made to sections which are not part of this manual. This manual was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This manual must not be copied without the written permission of YORK Refrigeration and the contents must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

This manual describes the compressor and its component parts as well as safety instructions/regulations. Moreover, the manual explains the different settings that can be of assistance to those who are responsible for the daily operation and maintenance of the equipment. To prevent any accidents, assembly and disassembly of components should only be carried out by authorized personnel. It is essential that the operating personnel familiarize themselves with the contents of this manual in order to ensure a proper and efficient operation. YORK Refrigeration is not liable for damage oc-

In the space below you may enter the name and address of your local YORK Representative

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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signs and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification of YORK Refrigeration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Pipe System Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vessel Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signs in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Sign: CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Sign: High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Label: The Temperature of Tangible Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Label: Internal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety during Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Texts Marked with Danger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Texts Marked with Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Texts Marked with Caution! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Instructions and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting and Carrying Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Relocation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-Up and Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials Used with this Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for Accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for Accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant no.: R134a - R505A - R507 - R22, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Rules for First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the Operator as well as the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Furthermore, it can be said about refrigerants: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging a Refrigeration Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 9 10 11 12 12 14 14 14 15 15 15 16 16 17 17 17 17 19 19 19 20 20 20 21 21 21 22 23 23 23 23 24 24 24 24 25 26 27 28 28

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Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Areas of Application of the Reciprocating Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . Description of the Compressors Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One-stage Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-stage Compressors Type TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion of TSMC Compressors from Two-stage to One-stage . . . . . . . . . . . . . . . . . . . Oil Separator Type OVUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting an Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Return to the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermodynamic Liquid Trap (TLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Return in Connection with Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity Regulation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity Regulation and Unloading of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic Drawings, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable speed drive (VSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling of the Intermediate Discharge Gas on TSMC Compressors . . . . . . . . . . . . . . . . . Automatic Regulation of Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining the Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting of Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Loss in the Cooling System in SMC/TSMC Compressors . . . . . . . . . . . . . . . . . . 1c: Cooling with Thermo Pump - R717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the Pumping Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ensuring Liquid to the Thermo Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Spare Parts Set: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical and Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections on SMC / TSMC Mk4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections for T/SMC104-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 29 31 33 33 43 43 44 45 46 47 47 47 48 50 51 52 55 57 58 58 60 61 62 70 71 72 74 77 79 79 81 81 81 83 88 89 92 94 95 98 99 99 100 100 105 108 110

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Control of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Pressure Transmitters marked PT1, PT2 and PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Element for Oil Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Data for the SMC 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight of Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Sketches of Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planning the Machine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Limits Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of Rotation of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choice of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Torque of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start up torque SMC 100 R717 25% load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moment of Intertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of Rotation of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling of Compressor and Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Drive for SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction of V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laying the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting of Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise from Compressors and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise Data for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverberation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration Data for Compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pressure Levels for Standard Compressors and Components . . . . . . . . . . . . . . . . . Charging the Compressor with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Lubricating Oil for SABROE Reciprocating Compressors . . . . . . . . . . . . . . . . . Oil Changing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 111 113 115 116 118 119 120 124 125 140 141 141 143 144 146 147 148 149 151 153 153 155 157 158 159 161 164 166 170 171 173 175 176 177 177 186 187 191 192 197 198 199 211 213 213 213

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Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting Accessories and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting and Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Materials which are not Reusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Equipment to the Mounting Site after Unloading and Unpacking . . . . . . . . . . . Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Alignment of Unit against Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting on Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Directly on Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Alignment of Compressor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Alignment of Motor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting and alignment of coupling type AMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Achieving correct centre height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Achieving parallel shafts in vertical plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Achieving Parallel Shafts in Horizontal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Achieving Correct Centre Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Achieving Parallel Shafts in Vertical Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Connecting Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Check of the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Directly Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 213 214 214 214 214 214 214 214 215 215 215 215 215 215 216 216 217 218 218 218 219 219 220 221 222 222 222 223 223 223 224 224 224 225 226 228 230 231 233 233 233 233 233 234 234 234 234

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Oil Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromechanical Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Transducers, marked PT1, PT2, PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensors, marked TT5, TT6 and TT7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . . Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot and Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Control and Alarm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recording Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations for Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Mode UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations before Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

234 234 235 235 236 236 236 236 236 237 237 237 239 240 243 243 243 243 244 244 245 245 245 247 247 247 248 249 250 251 251 259 261 261 262 263 263 264 264 264 264 264

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Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations for Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Check of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations on the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Check of the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations before the First Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evacuation and Charging of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks to be Performed after Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compliance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conformity with EU Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Machine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Oil and Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Moments for Screws and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sundry Clearances and Check Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

265 265 266 266 266 266 266 266 266 266 266 267 268 269 269 271 271 273 273 273 273 273 274 274 275 277 278 279

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2. Signs and Warnings


The purpose of this document is to describe: How YORK Refrigeration equipment can be identified. All warning signs used on equipment delivered by YORK Refrigeration. How information important to the safety of personnel and equipment is presented in instructions belonging to equipment delivered by YORK Refrigeration. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

This document is intended for all user categories. This document describes the importance of the individual signs which are attached to the YORK Refrigeration products. 02 signs and warnings.fm Before a compressor/unit is put into operation it must be provided with the warning signs corresponding to the actual type of compressor/unit in accordance with the rules and regulations in force.

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before starting the installation process. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment

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Identification of YORK Refrigeration Equipment


All YORK Refrigeration equipment can be identified by one or several name plates placed as illustrated by the following drawing: Fig. 2.1 2 1

1. Compressor name plate 2. Vessel name plate 3. Unit pipe system name plate

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Unit Pipe System Name Plate


Fig. 2.2 Unit Pipe System Name Plate
DK 8270 Hjbjerg
Unit Pipe System Identification No Design Code Approval No Pressure System Fluid/Group Allowable Pressure Max Leak Test Pressure PS PT LP HP Type

If the unit has been approved by an authority, the design code will be shown here. Approval no If the unit has been approved by an authority, the approval no will be shown here. Pressure system Low pressure side of compressor piping is referred to as LP. High pressure side of compressor piping is referred to as HP. Fluid/Group Refrigerant designation according to ISO817 or fluid group according to directive 67/548/EEC. Max allowable pressure Shows max allowable pressure relative to atmospheric pressure for which the pipe system has been designed. Leak test pressure, PT Shows the pressure with which the pipe system has been leak tested. Design temperature, TS Shows min and max temperatures for which the pipe system including components have been designed. CE xxxx The four digits compose the registration no of the notified body in charge of the assessment modules for the vessel.

Refrigeration
2516-328
Year

Bar Bar

Design Temperature TS Min/max 0062

02 signs and warnings.fm

The unit pipe system name plate is positioned on the frame - (see 3. Unit pipe system name plate). The name plate contains the following information: Type Manufacturer's type designation. Year Year of manufacture. Identification no Individual no for identification of supplied pipe system. Design code For PED orders: EN 378-2

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Compressor Name Plate


Fig. 2.3 Compressor Name Plate

Vessel Name Plate


Fig. 2.4 Vessel Name Plate

DK 8270 Hjbjerg
Compressor Type Nominal Speed Swept Volume Allowable Pressure Test Pressure No

Refrigeration
2516-327
Year

Refrigeration
DK 8270 Hjbjerg
Beholder/Vessel/ Behalter Type No

2516-326
r Year Jahr

RPM m3/h bar bar

Beregningsnorm/Design code/ Berechnungsnorm Godkendelsesnr Approval no Abnahme nr


/CAT. Svb/Shell/Mantel Rr/Tube/Rohr

The compressor name plate is positioned on the compressor - (see 1. Compressor name plate). The plate contains the following information: Compressor no Compressor manufacturing number. Year Year of manufacture. Type Manufacturer's type designation. Nominal speed Shows rotational speed of drive shaft at typical running condition. Swept volume Shows swept volume of compressor in m3/h at nominal speed. Allowable pressure Shows max working pressure of compressor. Test pressure Shows pressure at which compressor enclosure has been strength tested.

Side/Seite Medie/Media Tilladeligt tryk/Allowable pressure/ZulsPS siger Druck Tilladelig temp./Allowable temp./Zulssiger Temp. Volumen/ Volume
0062 V

bar
C
-L.

The vessel name plate is positioned on the shell of the vessel (see 2. Vessel name plate). The name plate contains the following information: Vessel no Vessel number stated by YORK Refrigeration. Year Year of manufacture. Type Manufacturer's type designation. Design code Shows the design code according to which the vessel was manufactured. Approval no/CAT Shows the approval no of the vessel issued by the relevant authority as well as the category according to PED 97/23/EEC, Article 9. Side Refers to the columns Shell and Tube.

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Media Shows the refrigerant designation according to ISO817. Allowable pressure, PS Shows min and max pressure relative to atmospheric pressure for which the vessel or vessel part has been designed.

Allowable temperature, TS Shows min and max temperatures for which the vessel has been designed. Volume Shows volume of the vessel in litres. CE xxxx The four digits compose the registration no of the notified body in charge of the assessment modules for the vessel.

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In the following section all signs which may be found on the equipment are described. However, the number of signs may vary from product to product.

The Sign: High Voltage

WDanger
HIGH VOLTAGE! Before working on any electrical circuits, turn the machine Main Disconnect Device OFF and lock it. Dismantle the main fuses to the compressor unit. Unless expressly stated in applicable YORK Refrigeration documentation or by a YORK Refrigeration Field Service Representative, do NOT work with the electrical power ON. Any work with the electrical power ON should be performed by a YORK Refrigeration Field Service Representative. The customer and subsequent transferees must make sure that any other person performing work with the electrical power ON is trained and technically qualified.

Signs in Instructions The Sign: CAUTION


A CAUTION tag like the one illustrated below is fixed to the compressor. The sign imposes the users to read the Safety Precautions section in the manual before handling, operating or servicing the compressor and unit.

Caution

Before handling, installing, operating or servicing the compressor and unit, read the Safety Precautions section in the Operating Manual. It is the responsibility of the operator or his employer that the Operating Manual is always available. This sign must not be removed nor be damaged in any way.

Antes de manejer, instalar, poner en marcha o dar servicio al compresor y la unidad, leer la seccin Precauciones de seguridad en el Libro de Instrucciones. Es respondabilidad del operaro o de su patrn, que el libro de instrucciones permanezca siempre al alcance de la mano. Esta seal no debe de ninguna manera 2516-297 suprimirse o daarse.

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The Label: The Temperature of Tangible Surfaces


When a compressor is working, the surfaces which are in contact with the warm discharge gas will also get warm. However, the temperature depends on the refrigerants used as well as the operating conditions of the compressor. Often the temperature exceeds 70C [158 F], which for metal surfaces may cause skin burns even at a light touch. Consequently, the compressors are equipped with yellow warning labels signalling that pipes, vessels and machine parts will become so hot during operation that your skin will get burnt if you touch them for one second or more. 02 signs and warnings.fm

Pfyldt beskyttelsesgas Charged with inert gas Enthlt Schutzgas Charg du gaz protecteur Contiene gas protector

N2 0,2 bar 3 PSI 1534-169

Other Warning Labels

Hazardous substance!

Dangerous noise level, use hearing protectors!

Internal overpressure!

The Label: Internal Protection


Compressor blocks and units are usually delivered without any refrigerant or oil. To protect the compressors against internal corrosion, they are delivered evacuated of all atmospheric air and charged with Nitrogen (N2) to an overpressure of 0.2 bar [3 psi]. In such cases a yellow label like the one shown below is affixed to a visible spot on the compressor.
Cold surfaces!

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Emergency Stop
Fig. 2.5 Emergency stop on the reciprocating compressor unit

Switch off all electric components on the compressor/unit before the dismantling/servicing. Make sure that there is neither overpressure nor any refrigerant in the part to be dismantled. Close all necessary stop valves. Use gloves and safety goggles and make sure to have a gas mask ready for use. Use the prescribed tools and check that they are properly maintained and in good working condition. In explosion-proof areas, use tools especially suited for this specific purpose. When dismantling the top covers, attention should be paid to the considerable spring force beneath the covers. When the screws are loosened, the cover must lift itself from the frame as described in the instruction manual.

Electromechanical control system

Emergency stop, mounted when installing the unit

UNISAB II control system

Emergency stop

Fig. 2.6
Springs Top cover

Safety during Service


Before dismantling or servicing a compressor or unit attention should be paid to the following points: Read the Safety Precautions in section 3 before opening the compressor and other parts of the refrigeration plant. Make sure that the motor cannot start up inadvertently. It is recommended to remove all main fuses. Before dismantling the side covers, empty the crankcase of its oil content. Check that the heating rod in the crankcase is de-energized.

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Warnings in Instructions
This section describes warnings used in instructions pertaining to YORK Refrigeration equipment. Information of importance to the safety of personnel or equipment is given at three levels. Danger! Warning! Caution!

Failure to observe information marked with Danger! may cause death or serious injury to personnel or even to a third party.

Texts Marked with Warning!


The example below shows how information of importance to the safety of involved personnel or of major importance to the safety of the equipment is presented.

There is an important distinction between these three levels. However, as shown below, the principle is the same at all three levels. Note: Information is sometimes given in a Note. A Note is used to emphasise information but it is never used for information vital to the safety of personnel and equipment.

WWarning!
Risk of damage to compressor! Always consult your supplier before using a compressor under operating conditions outside the specified working range.

02 signs and warnings.fm

Texts Marked with Caution!


The example below shows how information vital to the safety of involved personnel is presented.

Texts Marked with Danger!


The example below shows how information vital to the safety of involved personnel is presented.

WDanger!
Risk of electrical shock! Always turn off the main switch before servicing the unit! Contact with high voltage may cause death or serious injury.

WCaution!
Risk of incorrect viscosity! Always make sure that all oils used are mixable without causing chemical reactions. Chemical reactions might have serious effects on the viscosity. Failure to observe information marked with Caution! may cause damage to the equipment.

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3. Safety Precautions
The purpose of this document is to provide general safety precautions for this equipment. Additioal safety precautions relating to a specific task are given in the corresponding documents. The safety precautions are intended for all user categories. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted. maintenance personnel in practicing good shop safety procedures. Operator and maintenance personnel must read and understand these precautions completely before operating, setting up, running or performing maintenance on the compressor/unit. These precautions are to be used as a supplement to the safety precautions and warnings included in: a. b. c. All other manuals pertaining to the compressor/unit. Local, plant and shop safety rules and codes. National safety rules and regulations.

03 safety precautions.fm

General Safety Instructions and Considerations Personal Safety


Owners, operators, set-up, maintenance and service personnel must be aware that constant day-to-day safety procedures are a vital part of their job. Accident prevention must be one of the principal objectives of the job, regardless of the activity involved. Know and respect the compressor/unit. Read and carry out the prescribed safety and checking procedures. Make sure that everyone who works for, with or near you fully understands and - more importantly - complies with the following safety precautions and procedures when operating this compressor/unit. Observe the safety warnings on the compressor/unit. Use safety equipment. Wear approved eye or face protection as well as gloves when working with

W Danger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

W Warning!
Read related safety precautions before operating the compressor/unit. Failure to follow safety instructions may result in serious personal injury or death. Important! The safety precautions for this YORK Refrigeration compressor have been prepared to assist the operator, programmer and

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parts containing refrigerant and lubricating oil. Safety shoes with slip-proof soles can help you avoid injuries. Keep your safety equipment in good condition. Never operate or service this equipment if affected by alcohol, drugs or other substances or if in a condition which decreases alertness or judgment.

Before lifting or carrying a compressor/unit or other parts, determine the weight and size by means of e.g. tags, shipping data, labels, marked information or manuals. Use power hoists or other mechanical lifting and carrying equipment for heavy, bulky or unwieldy objects. Use hook-up methods recommended by your safety department and familiarise yourself with the signals for safely directing a crane operator. Never place any part of your body under a suspended load or move a suspended load over any other persons. Before lifting, be certain that you have a safe spot for depositing the load. Never work on a component while it is hanging from a crane or any other lifting mechanism. If in doubt as to the size or type of lifting equipment, the method and procedures to be used in connection with lifting, contact YORK Refrigeration before proceeding to lift the compressor, motor, unit or its components. Always inspect slings, chains, hoists and other lifting devices prior to use. Do not use lifting devices which are defective or in a questionable condition. Never exceed the lifting capacity of cranes, slings, eyebolts and other lifting equipment. Follow standards and instructions applicable to any lifting equipment used. Before inserting an eyebolt, be certain that both the eyebolt and the hole have the same size and type of threads. To attain safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged.

Work Area Safety


Always keep your work area clean. Dirty work areas with such hazards as oil, debris or water on the floor may cause someone to fall onto the floor, into the machine or onto other objects resulting in serious personal injury. Make sure your work area is free of hazardous obstructions and be aware of protruding machine members. Always keep your work area tidy so you are able to escape should a dangerous situation arise. Report unsafe working conditions to your supervisor or safety department.

Tool Safety
Always make sure that the hand tools are in proper working condition. Remove hand tools such as wrenches, measuring equipment, hammers, etc. from the compressor/unit immediately after use.

Lifting and Carrying Safety


Contact YORK Refrigeration if you have any questions or if you are not sure about the proper procedures for lifting and carrying.

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W Warning!
Failure to follow safety instructions on this page may result in serious personal injury or death.

Safety guards, shields, barriers, covers and protective devices must not be removed while the compressor/unit is operating. All safety features, disengagements and interlocks must be in place and function correctly before this equipment is put in operation. Never bypass or wire around any safety device. Keep all parts of your body off the compressor/motor/unit during operation. Never lean on or reach over the compressor. During operation, pay attention to the compressor unit process. Excessive vibration, unusual sounds, etc. can indicate problems requiring your immediate attention.

Installation and Relocation Safety


Before lifting the compressor, unit or other parts of the plant, consult the instruction manual or YORK Refrigeration for proper methods and procedures. An electrician must read and understand the electrical diagrams prior to connecting the machine to the power source. After connecting the machine, test all aspects of the electrical system for proper functioning. Always make sure that the machine is grounded properly. Place all selector switches in their O or neutral (disengaged) position. The doors of the main electrical cabinet must be closed and the main disconnect switch must be in the O position after the power source connection is complete. Before starting the compressor for the first time, make sure that all the motors rotate in the indicated direction.

03 safety precautions.fm

Maintenance Safety
Do not attempt to perform maintenance on the compressor unit until you have read and understood all the safety instructions. Assign only qualified service or maintenance personnel trained by YORK Refrigeration to perform maintenance and repair work on the unit. They should consult the service manual before attempting any service or repair work and contact YORK Refrigeration in case of questions. Use only YORK Refrigeration replacement parts; other parts may impair the safety of the compressor/unit. Before removing or opening any electrical enclosure, cover, plate or door, be sure that the Main Disconnect Switch is in the O position and the main fuses are dismantled. If any tool is required to remove a guard, cover, bracket or any basic part of this compressor, place the Main Disconnect Switch in the O position and lock it in the O position. If possible, post a sign at the disconnect switch indicating that main-

Set-Up and Operation Safety


Read and understand all the safety instructions before setting up, operating or servicing this compressor. Assign only qualified personnel instructed in safety and all machine functions to operate or service this compressor. Operators and maintenance personnel must carefully read, understand and fully comply with all warnings and instruction plates mounted on the machine. Do not paint over, alter or deface these plates or remove them from the compressor/unit. Replace all plates which become illegible. Replacement plates can be purchased from YORK Refrigeration.

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tenance is being performed. Dismantle main fuses to the unit.

W Danger HIGH VOLTAGE!


Before working on any electrical circuits, place the Main Disconnect Device of the compressor/unit in the "OFF" position and lock it. Dismantle the main fuses to the compressor unit. Unless expressly stated in applicable YORK Refrigeration documentation or by appropriate YORK Refrigeration Field Service Representative, do NOT work with the electrical power "ON". If such express statement or advice exists, work with the electrical power "ON" should be performed by a YORK Refrigeration Field Service Representative. The customer and subsequent transferees must make sure that any other person performing work with the electrical power "ON" is trained and technically qualified. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN DEATH OR SERIOUS PERSONAL SHOCK INJURY. When maintenance is to be performed in an area away from the disconnect, and the switch is not locked, tag all start button stations with a DO NOT START tag. Adequate precautions such as warning notices or other equally effective means must be taken to prevent electrical equipment from being activated electrically when maintenance work is being performed.

When removing electrical equipment, place number or labelled tags on those wires not marked. If wiring is replaced, be sure it is of the same type, length, size and has the same current carrying capacity. Close and fasten all guards, shields, covers, plates or doors securely before power is reconnected. An electrician must analyse the electrical system to determine the possible use of power retaining devices such as capacitors. Such power retaining devices must be disconnected, discharged or made safe before maintenance is performed. Working space around electrical equipment must be clear of obstructions. Provide adequate illumination to allow for proper operation and maintenance.

Materials Used with this Product


Always use YORK Refrigeration original spare parts. Please note the type of refrigerant on which the compressor operates as well as the precautions that need to be taken as described in the following sections: First aid for accidents with ammonia. First aid for accidents with HFC/HCFC. First aid for accidents with HC. First aid for accidents with CO2 Protecting the operator as well as the environment.

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First Aid for Accidents with Ammonia (Chemical formula: NH3 - refrigerant no.: R717)

W Warning!
No plant can ever be said to be too safe - safety is a way of life.

First Aid Measures


Inhalation: Immediately, move affected personnel into fresh air and loosen clothing restricting breathing. Call a doctor/ambulance with oxygen equipment.

General
Ammonia is not a cumulative poison. It has a distinctive, pungent odour that even at very low, harmless concentrations is detectable by most persons. Since ammonia is self-alarming, it serves as its own warning agent so that no person remains voluntarily in hazardous concentrations. Since ammonia is lighter than air, adequate ventilation is the best means of preventing an accumulation. Experience has shown that ammonia is extremely hard to ignite and under normal conditions a very stable compound. At extremely high, though limited concentrations, ammonia can form ignitable mixtures with air and oxygen and should be treated with respect.

Keep the patient still and warmly wrapped in blankets. If mouth and throat are burnt (freeze or acid burn) and the patient is conscious, let him drink water in small mouthfuls. If the patient is conscious and mouth and throat are not burnt, feed him sweetened tea or coffee (never feed an unconscious person). Oxygen may be given to the patient, but only when authorised by a doctor. If the patient stops breathing, apply artificial respiration. Eyes: In case of injuries from liquid splashes or concentrated vapour, immediately rinse with water (preferably using an eye rinser) and consult a doctor. Continue rinsing until otherwise stated by a doctor. If the affected person wears contact lenses these must be removed before the rinsing. Skin: In case of burns from liquid splashes or concentrated vapour, immediately wash with large quantities of water until the pain stops. Consult a doctor about actual burns. After washing, apply wet compresses - wetted with a sterile isotonic (0.9%) NaCl-solution (salt water) - to affected areas until medical advice is available.

03 safety precautions.fm

Basic Rules for First Aid


Always call a doctor immediately. Be prepared: Keep an irrigation bottle available containing a sterile isotonic (0.9%) NaCl-solution (salt water). A shower or a water tank should be available near all bulk installations with ammonia. When applying first aid, the persons assisting must be duly protected to avoid further injuries.

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First Aid for Accidents with HFC/HCFC Refrigerant no.: R134a - R505A - R507 - R22, etc.

W Warning!
No plant can ever be said to be too safe - safety is a way of life.

Basic Rules for First Aid


When affected persons are moved from low-lying or poorly ventilated rooms where high gas concentrations are suspected, the rescuer must wear a lifeline and be under constant observation from an assistant outside the room. Do not use adrenaline or similar heart stimuli. Inhalation: Immediately move affected persons into fresh air. Keep them still and warm and loosen clothing restricting breathing. If the patient is unconscious, call a doctor/ambulance with oxygen equipment immediately. Apply artificial respiration until a doctor authorizes other treatment. Eyes: Immediately rinse with water (preferably using an eye rinser) and consult a doctor. Continue rinsing until otherwise stated by a doctor. If the affected person wears contact lenses these must be removed before the rinsing. Skin: In case of frost-bite, immediately rinse with luke-warm water (max. 37C) and remove all clothes impeding blood circulation. Consult a doctor. Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out hermetic compressors.

General
HFC/HCFC form colourless and invisible gasses which are heavier than air and smell faintly of chloroform at high concentrations. Characteristics: non-toxic non-inflammable non-explosive non-corrosive

When heated to above approx. 300C, they break down into toxic, acid gas components, which are strongly irritating and aggressive to nose, eyes and skin and generally corrosive. Besides the obvious risk of unnoticeable, heavy gases displacing the atmospheric oxygen, inhalation of larger concentrations may have an accumulating, anaesthetic effect which may not be immediately apparent. 24 hours medical observation is therefore recommended.

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Protecting the Operator as well as the Environment

W Warning!
No plant can ever be said to be too safe - safety is a way of life. Increasing industrialisation threatens our environment. It is therefore absolutely imperative to protect nature against pollution. To this end, many countries have passed legislation in an effort to reduce pollution and preserve the environment. This legislation applies to all fields of industry, including refrigeration, and must be complied with. Pay extra attention to the following substances: 03 safety precautions.fm refrigerants cooling media (brine, etc.) lubricating oils Refrigerants usually have a natural boiling point considerably below 0C. This means that liquid refrigerants can be extremely harmful if they come into contact with skin or eyes. High concentrations of refrigerant vapours can be suffocating when they displace air.

If high concentrations of refrigerant vapours are inhaled, they will attack the human nervous system. When halogenated gasses come into contact with open flame or hot surfaces (over approx. 300C), they will decompose to produce poisonous chemicals. These have a very pungent odour and will thus warn personnel of their presence. At high concentrations R717 causes respiratory problems. When the amount of ammonia vapour in air is between 15 and 28 vol. % the combination is explosive and can be ignited by an electric spark or open flame. Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls below that of the mixture ratio stated. Usually the strong smell of ammonia will warn personnel before the concentration becomes dangerous. The following table shows the values for the max. permissible refrigerant content in air measured in volume %. Certain countries may, however, have official limits different from the ones stated.
Ammonia HCFC R410a R507 R22 R717 R744

Halogenated refrigerants HFC R134a TWA Time weighted average during a week Warning smell Unit 0.1 Vol.% Vol.% 0.2 0.1 0.1 0.1 0.1 0.1 R404a R407C

CO2

0.005

0.5

0.002

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Furthermore, it can be said about refrigerants:


HFC/HCFC If released into the atmosphere, halogenated refrigerants of the type HCFC (e.g. R22) will contribute to the depletion of the ozone layer in the stratosphere. The ozone layer protects the earth from the ultraviolet rays of the sun. Refrigerants of the types HFC and HCFC are greenhouse gases which contribute to an intensification of the greenhouse effect. They must, therefore, never be released into the atmosphere. Use a separate compressor to draw the refrigerant into the plant condenser/receiver or into separate refrigerant cylinders. Ammonia Ammonia is easily absorbed by water: At 15C 1 litre of water can absorb approx. 0.5 kg liquid ammonia (or approx. 700 litres ammonia vapour). Even small amounts of ammonia in water (2-5 mg per litre) are enough to wreak havoc with marine life if allowed to pollute waterways and lakes. As ammonia is alkaline, it will damage plant life if released into the atmosphere in large quantities.

Hydro carbons are odourless and non-toxic gasses. Specific mixtures of air and gas create danger of explosion. As the gasses are heavier than air, they will be concentrated at the lowest possible level in case of leaks.

Carbon Dioxide (CO2) Carbon dioxide (CO2) is a greenhouse gas with a GWP (Global Warming Potential) factor of 1. It is found in the atmosphere in a concentration of 0.036 vol. % (360 parts per million, ppm). As CO2 is extracted from atmospheric air, it can safely be released into the atmosphere and does not contribute to enhancing the greenhouse effect. The boiling point for CO2 is -78.5C at 1.013 bar. CO2 is an odourless, non-toxic non-inflammable gas. At concentrations higher than 5000 ppm the gas can be dangerous for humans. The gas is heavier than air and will thus be concentrated on the lowest level of the room in case of a leak. In closed rooms the gas can displace oxygen and cause suffocation.

Refrigerant evacuated from a refrigeration plant must be charged into refrigerant cylinders intended for this specific refrigerant. If the refrigerant is not to be reused, return it to the supplier or to an authorized incineration plant. Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogenated refrigerants.

Hydro Carbons (HC) HC gasses are a group of B1 refrigerants characterized as very flammable.

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3. Safety Precautions

Purging a Refrigeration Plant


If it is necessary to purge air from a refrigeration plant, make sure to observe the following: Refrigerants must not be released into the atmosphere (exept CO2). When purging an R717 plant, use an approved air purger. The purged air must pass through an open container of water for any remaining R717 to be absorbed. The water mixture must be sent to an authorized incineration plant. Halogenated refrigerants cannot be absorbed by water. An approved air purger must be fitted to the plant. This must be checked regularly by use of a leak detector.

Note: The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation.

03 safety precautions.fm

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Cooling Media
Salt solutions (brines) of calcium chloride (CaCl2) or sodium chloride (NaCl) are often used. In recent years alcohol, glycol and halogenated compounds have been used in the production of brine. In general, all brines must be considered harmful to nature and they must be used with caution. Be very careful when charging or purging a refrigeration plant. Never empty brines down a sewer or into the environment. The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incineration plant.

protective equipment - goggles and gloves - when charging oil. Refrigeration compressors are lubricated by one of the following oil types depending on the refrigerant plant type, and operating conditons. Mineral oil (M oil) Hydro treated mineral oil (H oil) Semi-synthetic oil (mix of M oil and synthetic oil) Alkyl benzene-based synthetic oil (A oil) Polyalphaolefine-based synthetic oil (PAO oil) Polyalkylen Glycol-based synthetic oil (PAG oil) Ester oil (E oil)

Lubricating Oils

WWarning!
When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material Safety Data Sheet). Always avoid direcst contact with the oil as this may cause skin allergies. Always use

See the section Selecting lubricating oil for YORK Refrigeration compressors in section 6, Technical Data. When changing the oil in the compressor or draining oil from the vessel of the refrigeration plant, always collect the used oil in containers marked waste oil and send them to an approved incineration plant. It is not recommended to re-use oil.

Note: These instructions only provide general information. The owner of the refrigeration plant is responsible for ensuring that all codes, regulations and industry standards are complied with.

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4. Technical Description

4. Technical Description
The purpose of this document is to describe the intended purpose, the physical characteristics and the functions of the unit. This document is primarily intended for designers, service engineers, prospective customers, sales personnel and personnel undergoing training. This document was produced by: YORK Refrigeration Chr. X's Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted. frigerants: R717 - R22 - R134a - R407C R404A - R507 - R600 - R600A - R290 LPG. This manual only deals with the ones written in bold letters. Compressor types SMC 100 and TSMC 100 in an E execution are as standard compressors used with R717 only. The compressors can be used with other refrigerants, but only following a written agreement with YORK Refrigeration. SMC 100 and TSMC 100 compressors in S, L or E executions may be used at a max discharge design pressure of 25 bar. See Test Pressure Levels for Standard Compressors and Components in section 6. The compressors are approved for application in an explosion-prone environment, provided they have been fitted with explosion-proof equipment. This can be seen from the Ex nameplates, , fixed on each unit.

04 technical description.fm

Areas of Application of the Reciprocating Compressor Unit


Application In view of preventing an unintended application of the compressor, which could cause injuries to the operating staff or lead to technical damage, the compressors may only be applied for the following purposes: As a refrigeration compressor with the number of revolutions pr. minute specified by YORK Refrigeration and the operating limits as stated in this manual or in a written agreement with YORK Refrigeration. Compressor types SMC 100 and TSMC 100 in an S or L execution can - as standard compressors - be used with the following re-

Fig. 4.1

T2516273_0

Please, note that specially made tools which cannot cause any sparks must be used in connection with maintenance work on the compressor.

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WWarning!
The compressor must NOT be used: For evacuating the refrigeration plant of air and moisture, For putting the refrigeration plant under air pressure in view of a pressure testing, As an air compressor.

WDanger!
YORK Refrigeration does not take any responsibility for injuries to personnel or damage to equipment resulting from using this equipment for other purposes than the ones stated above. Application of Combustion Engines If combustion engines are installed in rooms containing refrigeration machinery or rooms where there are pipes and components containing refrigerant, make sure that in case of leakage the combustion air for the engine comes from an area in which there is no refrigerant gas. Failure to do so will involve a risk of lubricating oil from the combustion engine mixing with refrigerant; at worst this may lead to corrosion and damage of the engine.

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4. Technical Description

Description of the Compressors Compressor Types


Reciprocating compressor types SMC 100 and TSMC 100 represent a series of open compressors with 4 to 16 cylinders in one and the same block. The cylinders are positioned in a V or W position and have the same internal diameter of 100 Fig. 4.2

mm. The series comprises 15 one-stage and 6 two-stage compressors with the following type designations: Compressors with 4, 6 and 8 cylinders are called short blocks whereas compressors with 12 and 16 cylinders are called long blocks.

Short Block

04 technical description.fm

SABROE

Long Block

One-stage compressors are designated SMC which is an abbreviation of SABROE Multi-cylinder Compressor. As for the two-stage compressors the letter T has been added to indicate Two stages. Further, the compressors can be delivered with the following three strokes, designated S, L or E, respectively:

Type S has an 80 mm piston stroke and is used with all approved refrigerants. Type L has a 100 mm piston stroke and is used with all approved refrigerants. Type E has a 120 mm piston stroke and is used only in connection with R717. The compressor has 50% more capacity than type S.

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The operating limits (including number of revolutions) depend on the compressor type and refrigerant. As the extension of the operating limits is an

ongoing process, please make sure that the diagram in question is the latest revision before making a conclusion.

Below are given some examples of type designations of the compressors: One-stage compressor Compressor type: Cylinder Diameter: 100 mm Number of Cylinders: 4-6-8-12 or 16 Stroke: S, L or E Two-stage compressor Compressor type: Cylinder Diameter: 100 mm Number of Cylinders: 8 or 16 Stroke: S, L or E An entire list of the compressor series can be seen in the table Technical Data for SMC 100 Series in Section 6, Technical Data. The type and version of the various compressors can be read from the name plate shown below. A name plate is fixed on every compressor. Similarly, the serial number of each compressor is stamped into the compressor block. The letter S, L or E, which refers to the compressor stroke, is stamped into the end surface of the crankshaft. Whenever contacting YORK Refrigeration about a compressor, please state its serial number. SMC 108 L

TSMC 116 S

DK 8270 Hjbjerg
Compressor Type Nominal Speed Swept Volume Allowable Pressure Test Pressure No

Refrigeration
2516-327
Year

RPM m3/h bar bar

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Compressor Description
With a few exceptions, all compressors of the SMC 100 or TSMC 100 types use the same spare parts as the ones described in the following section.

One-stage Compressors
The compressors are equipped with replaceable cylinder liners, pos. 19A, Fig. 4.3, which are made of special cast iron and are easy to dismantle for inspection. They are honed and surface hardened, which makes them very wear resistant. Underneath each top cover there are always two cylinders.

Fig. 4.3

SMC 100 Cylinder Liner Complete


21

20

19H

04 technical description.fm

19A

The pistons, pos. 18, are made of aluminium with two hard-plated piston rings and one oil scraping

ring ensuring optimum tightness, low oil consumption as well as long life.

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4. Technical Description

Fig. 4.4

Piston

a downward force during suction. This is different from the top of the LP pistons which are affected by a pressure lower than the suction pressure which gives the piston an upward force during suction. Fig. 4.5 Connecting Rod, SMC 100

18 17A

17B TSMC HP 17B SMC and TSMC LP

Suction valve, pos. 19H, which is of the ring plate type, is fitted at the top of the cylinder liner and can be removed together with the cylinder liner. Discharge valve, pos. 20, forms the top of the cylinder and is kept in place by a powerful spring, pos. 21. This spring is also called the safety spring as it enables the complete discharge valve to lift a little at particularly high pressures in the cylinder due to liquid or oil in the compressed gas (liquid slugging). Thus overloading of the bearings in the connecting rod is avoided. The compressor is designed for operation with liquid slugging for a short time only. If liquid slugging occurs (the sound of hard metal hammering), the compressor must be stopped and the cause must be removed. Connecting rod, pos. 17, Fig. 4.5 is made of cast iron with a large elongation after fracture. It has replaceable slide bearings, pos. 17A and B, at both ends on single stage compressors and on the first stage (LP) on TSMC. On the second stage (HP) on TSMC, the small end bearing is of the rolling element type. The reason for this is that the top of the HP pistons are affected by the intermediate pressure, which is higher than the suction pressure, and thus gives
17

Suction filter: All the compressors are equipped with very large built-in suction filters, pos. 34A, Fig. 4.6, with great filtering capacity which effectively filters off the dirt particles conveyed with the gas from the refrigeration plant to the compressor. The suction filters are made of stainless steel and, by dismantling the covers, pos. 34E, they are easy to pull out and clean. When a compressor is delivered, a fine-meshed filter bag, pos. 34B, has been fitted in the suction filters. The filter bag filters off the tiny rust particles that may pass the suction filters and is thus providing the compressor with considerable protection from dirt mixing with oil. The filter bags are used no longer than 50 hours after initial start up of the compressor. This also applies when changes, which may cause impurities in the suction gas, are made on the plant. After the 50 hours, the filter bags and the inserts for the filter bags pos. 34C must be taken out and discarded. Used filter bags

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4. Technical Description

must be disposed of according to existing environmental legislation, see also Section 11 Maintenance Instructions and Section 20 Final Disposal. Fig. 4.6 SMC 100 Filter Section and by-pass valve

24

34A

04 technical description.fm

34E 34B

34C

By-pass valve: The compressor is equipped with a built-in mechanical by-pass valve, Fig. 4.6 and Fig. 4.7, pos. 24, which safeguards the compressor against unintended over-pressure in case the Fig. 4.7 SMC/TSMC 100 - By-pass Valve

electric safety equipment should fail. The bypass valve acts as a kind of over-pressure safeguard between the discharge and suction side of the compressor.

24C

24B

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The by-pass valve is delivered pre-set, sealed and adjusted to the following opening pressures: Standard for SMC and TSMC (HP stage) compressors: 24 bar [348 psi]. Special for SMC - and TSMC (HP stage) compressors: 22 bar [319 psi]; this is only delivered following a specific order and applied in accordance with local rules and regulations concerning pressure vessels as e.g. oil separators. The current set pressure is stamped into the name plate pos. A. Standard for TSMC (LP stage) compressors: 12 bar [174 psi]. The by-pass valve is of the high-lifting type, which makes it robust and durable. Moreover, the by-pass valve is independent of the pressure on the suction side of the compressor. Consequently, it opens only when the pressure on the discharge side exceeds the set pressure compared to that of the atmosphere. Note: The by-pass valve should not be considered a safety valve. Fig. 4.8 SMC 104-108 Short Block

Fig. 4.9

TSMC 112-116 Long Block

49A

The crankshaft, pos. 16, Fig. 4.8, rests in large slide main bearings pos. 5 and 6 which are able to absorb both radial and axial loads. Both the main bearings and the connecting rod bearings at the large end of the connecting rod are easy to replace in connection with an overhaul of the compressor and need no additional finishing after remounting. The bearings are available in 0.5 mm undersize to be used for crankshafts that are ground to 0.5 mm undersize during a renovation. After having been ground to undersize, the crankshaft needs no surface hardening or the like, but can be used directly as bearing surface. The crankshaft is dynamically balanced for a smooth and vibration free operation and need no further balancing after the above-mentioned machining to undersize. In the SMC 112-116 compressors the crankshaft is also supported by an intermediate bearing, pos. 49A, .

6 16

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Fig. 4.10

SMC 112 - 116 and TSMC 116

Fig. 4.11

Oil pressure regulating valve


Pos. 22

49A

Pointed screw

The Oil suction strainer pos. 33A prevents dirt particles in the oil of the crankcase from entering the oil pump with a subsequent wear on the pump bearings. The filter is of the full flow filter type. The filter can be cleaned. 04 technical description.fm The oil pump, pos. 11A, Fig. 4.13, is built into the compressor and driven by the crankshaft by means of a coupling. The oil pump is a self-priming gear pump which takes the oil from the oil sump through an oil suction strainer in the crankcase, pos 33A, Fig. 4.12 and forces it through the full flow filter into the lubricating system. The oil pressure regulating valve, pos. 22, Fig. 4.11 regulates the oil pressure in the compressor lubricating system. It can be adjusted from the outside by means of a screw driver when the pointed screw, which locks the regulating screw, has been loosened. For variable speed driven compressors, the oil pressure has to be adjusted to the minimum oil pressure at minimum speed. Due to rising pressure drop at high oil flow, the pressure will rise when running at maximum rpm. Fig. 4.12 oil suction strainer

Pos. 33A

External oil filter, pos. 9A. After the oil pump, the oil is furthermore filtered in an external oil filter of the full flow filter type, pos. 9A, before it is led into the lubricating system. The filter element is a disposable filter and must be replaced by a new one as soon as its filtering ability has been used up. The replacement can be carried out without reducing the refrigerant pressure on the compressor.

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Fig. 4.13

Oil pump cover assembly

to the branch pos. 4F on the pump housing. After this, the compressor is ready for start up. The non-return valve, pos. 4L acts as a bypass valve when the differential pressure above the oil pump is too high.

4D 4E 4Q 4L

Fig. 4.14

Valves and filter on oil pump cover

4F 4K

11B 9A 11A 4L 9A 4E 4D 4F

4k

Shut-off valves, pos. 4K and pos. 4D are used for dismantling the oil filter. The shut-off valves must be completely open during operation to avoid pressure drops in the oil system. For additional information about function see oil diagram Fig. 4.15. The air purge valve, pos. 4E is used to reduce the pressure in the oil filter before dismantling. The valve pos. 4E further acts as a prelubrication valve. Prelubrication of the compressor must always be carried out before the initial start up and after a long period of standstill. This way the bearings and the oil system are lubricated and the oil pump is filled with oil. The hose from the prelubrication pump must be connected

The shaft seal, pos. 10, is a sealing component which prevents oil and refrigerant from the compressor interior from leaking into the atmosphere. The shaft seal is of the slide ring type, consisting of a plane, lapped cast iron slide ring which rotates with the crankshaft and seals against a stationary spring-loaded slide ring made of special carbon. The shaft seal is of the balanced type and consequently serves a universal purpose in view of operating conditions, refrigerants and oil types used for the compressor. The design of the shaft seal and coupling of the motor is such that the shaft seal can be removed from the compressor without removing neither compressor nor motor. This facilitates maintenance considerably.

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Fig. 4.15

Oil diagram

PDI 4N-1
H H

4L-1

4D-1

9A

4K-1

04 technical description.fm

4E-1

11A-1

33A-1

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4. Technical Description

Fig. 4.16

Shaft seal

Fig. 4.17

SMC 100 block Pump end

Pos. 10

23 1B

57

The heating rod, pos. 57, Fig. 4.17 keeps the oil warm when the compressor is not in operation. This reduces the refrigerant content in the oil and eliminates starting-up problems caused by oil foaming and subsequent insufficient oil pressure. While the compressor is operating, the heating cartridge can be switched off, but if it is problematic to maintain the oil temperature sufficiently high, it may be an advantage to keep the heating cartridge on during operation.

Oil draining valve, pos. 23, for draining and charging of oil. An inner socket at the draining valve ensures that the oil sump is properly drained so that the compressor does not have to be opened when changing oil and filters. The oil level glass, pos.1B, indicates the prescribed oil level in the crankcase. See Section 6, Technical Data - Charging the Compressor with Oil. Evacuating valve, pos. 42, Fig. 4.18, for evacuating the compressor of refrigerant or air after service.

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Fig. 4.18
25-3

SMC 104 - 108 Short Block


42 25-4

flanges for connection to ISO and ASME standard pipes. Pipe dimensions are indicated on the dimension sketches in Section 5, Physical and Connecting data. Instrumentation: As standard equipment the compressors are fitted with either an analogous reading and safety system consisting of pressure gauges, pressure switches and thermostat, or with a SABROE microelectronic reading and control system, UNISAB II, as shown in Fig. 4.19. Both systems are described in detail later in this section. Cooling of compressor and oil: On request the compressor can be delivered with a built-in cooling system with either water or refrigerant as described in the section, Cooling Systems for Compressors.

04 technical description.fm

The stop valves, pos. 25-3 and 25-4, are fitted on the compressor discharge and suction flanges for efficient blocking off of the compressor from the refrigeration plant. The stop valves have welding

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Instrumentation
39A -- 1 99

Fig. 4.19
UNIS AB II
31A 39B - 1 31C -- 1 30A 31C -- 1

4. Technical Description

SMC /TSMC 100 Mk4 - Engineering Manual

39 D 45J - 1 D 45

Analogous control and

safety system

Name plate

39A - 1 99

UNISAB II
31A 39B - 1 31C - 1 30A 31C - 1 -

39

D 45J - 1 D 45

Analogous control and safety system

Name plate

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4. Technical Description

Two-stage Compressors Type TSMC 100


The TSMC compressors are so-called compound machines in which the refrigerant gas is compressed in two stages. The compressor is divided into a low-pressure section, LP, and a high-pressure section, HP. The cylinders in the low-pressure section compress the gas from evaporating pressure, PE, to intermediate pressure, PI. During the compression the gas is heated and must consequently be cooled down in the intermediate cooling system before it reaches the high-pressure stage. At the high-pressure stage, the gas is compressed from PI to the condensing pressure PC. 04 technical description.fm The system is described in detail in Cooling of the intermediate discharge gas on TSMC compressors later in this section. The TSMC 100 compressors are available with 8 or 16 cylinders, divided as indicated: TSMC 108: 6 low-pressure (LP) cylinder 2 high-pressure (HP) cylinder TSMC 116: 12 low-pressure (LP) cylinder 4 high-pressure (HP) cylinder TSMC 100 compressors are connected to installations where the compression ratio (PC/PE) is higher than the permissible compression ratio for one-stage compressors. This is described in detail in Section 6, Technical Data, Operating Limits. As mentioned previously all compressor types in the SMC 100 and TSMC 100 series - with a few exceptions - are built up of the same components and with the same facilities. However, the TSMC 100 compressors deviate on the following points:

Compressor Block
The interior of the compressor block is constructed with suction chambers for both low pressure and high pressure stages. The pressure in the crankcase is the same as the suction pressure of the LP stage.

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4. Technical Description

Piston Pin Bearing


In the SMC and TSMC low-pressure stages the piston pin bearing consists of slide bearings, pos. 17B, Fig. 4.20. In the connecting rods of the high-pressure stage a needle bearing, pos.17B2, has been fitted. This is because HP pistons on two-stage compressors - as opposed to single stage and LP pistons - are often subject to uni-directional force.

Fig. 4.20

TSMC 100 Cylinder Liner Complete

17B TSMC HP 17A 17B TSMC LP

17

Similarly, an O-ring, pos. 19M, is used to seal the intermediate pressure chamber from the crankcase in which there is evaporating pressure. Fig. 4.21 TSMC cylinder liner

19M

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4. Technical Description

Suction Filters
In the TSMC compressors the two suction filters vary in design. The suction filter for the LP stage is of the same type as the ones for the SMC compressors and is characterised by square holes in the shell and openings at both ends. Fig. 4.22
TSMC 108

In the high-pressure stage a suction filter of the same size as the one for the LP stage has been fitted, but this has round holes in the shell and is closed at one end.

HP

Closed end and O-ring sealing

04 technical description.fm

LP

TSMC 116

LP

HP

Depending on the type of refrigerant and the suction and discharge pressures, a by-pass system is sometimes used to regulate the intermediate pressure PI in order to prevent it from falling below the specified pressure. The system is either built onto the compressor at the factory or mounted on the refrigeration plant if several two-stage compressors work in parallel.

The by-pass system is described in detail later in this section under Cooling of the Intermediate Discharge Gas on TSMC Compressors. The TSMC 100 compressors can be delivered with one or two oil separators depending on the type of refrigerant and area of application. Otherwise, the terms of delivery are the same as the ones described for one-stage compressors.

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4. Technical Description

Conversion of TSMC Compressors from Two-stage to One-stage


If necessary, it is possible to convert a two-stage compressor into a one-stage compressor. The following variations are possible: a. b. Altering the compressor and using the same refrigerant Altering the compressor and changing the refrigerant from R717 to HFC/HCFC at the same time Altering the compressor and changing the refrigerant from HFC/HCFC to R717 at the same time

3.

Changing the pipe connections on the discharge side. As the built-in channel, which connects the top covers on a onestage compressor, does not exist between the HP and LP top covers, this connection must be established externally. Changing the HP stage connecting rods to the single stage type (journal bearing in small end). The piston pins must be changed. Ensuring that the correct suction and discharge valves are fitted. Installing the correct by-pass valves. Adjusting the safety pressure controls.

4.

5. 6. 7.

c.

Generally, the conversion includes the following points: 1. 2. Replacing the suction filter with a normal one-stage suction filter on the HP side. Dismantling the pipe connection on the HP suction side and installing a standard cover, pos. 34 E.

Moreover, it is necessary to replace the compressor name plate and the name plates on the safety valves. Please contact YORK Refrigerations After Market Sales Department for further information.

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4. Technical Description

Oil Separator Type OVUR


The purpose of the oil separator is - under all kinds of operating conditions - to separate the oil which is conveyed with the disharge gas out of the compressor so that it will be led back to the compressor crankcase. The oil separator is mounted on the compressor unit and connected to the discharge gas outlet of the compressor as indicated in the drawing, Fig. 4.23. On some units the oil separator is not mounted. Fig. 4.23 Standard Compressor Unit
Oil Separator

Fig. 4.24

Oil Separator
A

04 technical description.fm

Mode of Operation
The discharge gas from the compressor flows through the oil separator, Fig. 4.24, from A to B, passing a number of filters in which the oil is separated from the discharge gas. The filters consist of a stainless steel wire mesh which usually needs no cleaning and which is not worn down. Consequently, the filters cannot be removed from the oil separator.

L
A: Discharge gas inlet B: Discharge gas outlet L: Oil return to compressor

Selecting an Oil Separator


As the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas, a series of oil separators of different sizes has been designed. See Section 6, Technical Data, Selecting an Oil Separator.

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4. Technical Description

Oil Return to the Compressor


The oil separated in the oil separator is usually conveyed directly back to the compressor crankcase by means of the differential pressure between the pressure of the oil separator, PC, and that of the crankcase, PE. As the return of gas from the discharge side to the suction side will have a negative effect on the plant, it is desirable to lead only the separated oil back to the crankcase. This is controlled by using a thermodynamic liquid trap (TLT) combined with a reliable solenoid valve which blocks the system at standstill. Furthermore, it makes it possible to delay the opening of the oil return after start up and thus allowing condensed refrigerant, if any, in Fig. 4.25 Solenoid Valve Controlled Oil Return
Compressor Oil separator

the oil separator to evaporate and not be led back to the crankcase. For plants which do not allow solenoid valves, a reliable float valve controlled system can be delivered at an additional price. A: Solenoid Valve Controlled Oil Return As illustrated in the drawing, Fig. 4.25, the oil from the oil separator is led to the compressor crankcase via valve block A and the TLT. In the oil separator at position C the pipe is inserted 10 mm into the end plate whereby any sediment can settle at the bottom of the oil separator.

Valve block A Pos. 80A-1 Solenoid valve Orifice Pos. 80B-1 stop valve

Filter

TLT valve Pos. 80C-1

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In valve block, pos. A, Fig. 4.26, the oil first passes a stop valve which is normally completely open. This is not a regulating valve and it is closed only during maintenance work on the compressor and during cleaning of the filter in the valve block. Fig. 4.26 Valve Block, pos. A, Oil Return

closed at dead coil whenever the compressor is stopped. When the compressor is operating, the solenoid valve is open, allowing the oil to flow to the compressor. As stated above it is recommended, however, to keep the solenoid valve closed for 20 to 30 minutes after start-up by means of a time relay (which may be ordered as an accessory part). Thus the oil is not returned to the compressor before the oil separator is warm and has evaporated any refrigerant which may have mixed with the oil at the bottom of the oil separator. This time function is built into the UNISAB II system.

Inlet

Nozzle

04 technical description.fm

The solenoid valve seat is available with various boring diameters and nozzle sizes. For this purpose 3.3 mm must be used. The coil for the solenoid valve can be delivered as a standard part with the following data: Table 4.1

Outlet

Wire mesh
220/230 Volt

Coil Sizes 50/60 Hz 50/60 Hz 50 Hz 10 Watt 10 Watt 10 Watt

From the stop valve the oil passes a wire mesh, which can be removed and cleaned.The filtered oil now passes the solenoid valve, which must be

115 Volt 240 Volt

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4. Technical Description

Thermodynamic Liquid Trap (TLT)


The purpose of the TLT valve is to ensure that only oil is led back to the compressor as warm discharge gas mixed with the oil will cause the compressor capacity to decrease. Fig. 4.27
3 2

The trap remains tightly closed until the loss of heat through the trap body lowers the control chamber pressure, allowing the inlet pressure to raise the disc and repeat the cycle. One side of the disc (3) is plain with a single scratch towards the outer edge, whereas the other side of the disc has a machined circular groove. The trap is supplied with the grooved side of the disc towards the seating faces and is suitable for clean operating conditions. If there are irregularities in the oil return, it may be due to impurities in the oil. The problem can be solved by unscrewing the cap, preferably using a ring spanner, and turning over the disc so that the plain side with a bleed scratch is towards the seating faces. Replace the cap - no gasket is required but a suitable high temperature anti-sieze grease without copper should be applied to the threads.

Thermodynamic Liquid Trap TLT

4 1 6 5

1 : Housing 2 : Cap 3 : Disc

4 : Strainer 5 : Strainer Cap 6 : Gasket

The TLT valve works in the following way: A thermodynamic liquid trap uses a disc to control the release of liquid and to trap gas. The trap cycles open and close to discharge liquid and closes tightly between discharges. The disc, which is the only moving part, rises and falls in response to dynamic forces produced by the gas flowing through the trap. Liquid and/or gas enters the trap through the central orifice, lifts the disc and is discharged through the outlet orifice. The gas passes along the underside of the disc at high velocity and collects in the control chamber above. The resulting pressure imbalance forces the disc downward onto the seating surfaces and stops the flow.

Mounting In principle, the liquid trap can function in all positions but to minimise uneven wear (and thereby achieving maximum life time) mounting it in a horizontal line with the cap up or down is recommended. See also Fig. 4.25. The surface of the connection is machined to make a tight sealing using Al gasket. Fig. 4.28 Principle piping diagram
Oil separator

TLT 15

EVRB

Reciprocating compressor

245893

Nozzle 3.3 mm

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4. Technical Description

B: Float Valve Controlled Oil Return The float valve is located in a separate float vessel, mounted on the side of the base frame and connected to the oil separator and compressor as illustrated on Fig. 4.29. Fig. 4.29 Float Valve Control Oil Return

The pipe connection with valve B acts as a pressure equalizer between the two vessels. The float can be dismantled for servicing.

Oil Return in Connection with Parallel Operation


If several compressors are running in parallel on the same refrigeration plant, it is expedient to adjust their oil level in the crankcase by means of an automatic system. This is particularly necessary in the case of HFC and HCFC plants in which the oil is returned to the compressors with the suction gas as it is not distributed evenly on all the compressors.

04 technical description.fm

However, also in modern, automated R717 refrigeration plants an automatic oil equalizing system can contribute to greater reliability, thus reducing the daily inspection tours. The following passages A, B and C include a description of the three systems most commonly used. The following passages describe each of the three systems in general. For more detailed information, please contact YORK Refrigeration.

To the compressor

The separated oil is drained through stop valves A and filter D to the float vessel C, and here the float valve opens at an increasing oil level and returns the oil to the crankcase.

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System A
System A is used where two or more compressors are working in parallel and where either HFC, HCFC or R717 is used as the refrigerant. It is a condition, however, that the compressors keep working at the same suction pressure. Fig. 4.30 Principle Diagram
Standard Oil seperator with solenoil valve controlled oil return Alternative Oil seperator with float valve controlled oil return

Principle diagram, Fig. 4.30, is an example of a plant with two compressors working in parallel on the same suction and discharge line.

5 1 2 3 4 10 14 9 7 6 3 4 7 2 1

6 14

8 9

12 11 13

15 16

Table 4.2
1. 2. 3. 4. 5. 6. 7. 8. Compressor Float valve Filter Stop valvet Oil separator Solenoid valve incl. nozzle (Fig. 4.30) Non-return valve Float valve 9. 10. 11. 12. 13. 14. 15. 16. Oil vessel Non-return valve,1 bar Solenoid valve Nozzle, dia. 3.3 mm Filter Heating cartridge Oil charging valve Oil level glass

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4. Technical Description

As illustrated in Fig. 4.31 a float valve, pos. 2, is fitted on each of the compressors in front of the oil level glass. This makes the oil level in the float house equal to that in the crankcase. This can be checked visually in the oil level glass. The complete float valve can be seen in Fig. 4.31. Fig. 4.31
Pipe connection

The oil vessel, pos. 9, is illustrated by the principle drawing, Fig. 4.32. Its size is calculated so that an extra amount of oil is available to ensure the oil level in the compressor. The total volume of the vessel should be approx. 50% of the oil volume in all the compressors, and the vessel should not be charged to more than 50%. This means that the amount of oil in the vessel corresponds to 25% of the total amount of oil in the compressor. The oil vessel must be equipped with: - heating rod, 240 W, pos. 14 - oil charging valve, pos. 15 - oil level glass, pos. 16

Float Valve Housing with Float Valve


Vent valve Oil level glass on compressor

04 technical description.fm

From the top of the oil vessel, pos. 9, a pipeline is taken to the suction side of the plant. The float controls a needle valve which opens at a falling oil level, letting the oil flow from the oil vessel, pos. 9, return to the compressor. This ensures a constant oil level in the compressor. Fig. 4.32
To common suction line
15

Oil Vessel, pos. 9

A non-return valve, pos. 10, Fig. 4.30, has been inserted in the pipeline, and this valve opens at a differential pressure of 1 bar. This way the pressure in the oil vessel will be 1 bar higher than the suction pressure in the plant. This is sufficient in order to squeeze the oil through the float valves, pos. 2, without causing foaming in the float valve houses.

16

14

240 W To float valves

Max. oil level

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4. Technical Description

The Oil Return Systems from the Oil Separators are the same as the ones described in Oil return to the compressor in this section. The only difference is that the oil return system is not connected to the compressor but taken to the common oil vessel, pos. 9. Solenoid valve, pos. 6, closes whenever the actual compressor stops. In case the oil return system from the oil separators is controlled by a float valve, which is also described in this section, it will be necessary to mount a pipe connection to the discharge pipe as illustrated in Fig. 4.33. This ensures a slight gas flow to the oil vessel, pos. 9, and consequently overpressure that presses the oil out to the compressors through

float valves, pos. 2. Solenoid valve, pos. 11, closes when the plant stops and all the compressors are stopped. Fig. 4.33 Oil separator with float valve controlled oil return
5

8 14 9 11

12 13

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4. Technical Description

System B
System B is used where more than two compressors are working in parallel but where they do not have any joint suction line. The refrigerant may be HFC, HCFC or R717. Fig. 4.34
To condenser

Principle diagram, Fig. 4.34, is an example of a plant with two compressors working in parallel but which do not have the same suction pressure, PE+, PE-.

ET 5 ET+ 6 A B 6 5

Alternative Oil seperator with float valve controlled oil return

04 technical description.fm

6a

2a 10

7 3 4

6b

2b

14 7 15 9

8 9 11

12 13

3 4

14

16

Table 4.3
A-B 2a-2b. 3. 4. 5. 6a-6b. 7. 8. Compressor Level Switch Filter Stop valve Oil separator Solenoid valve incl. nozzle (Fig. 4.34) Non-return valve Float valve 9. 10. 11. 12. 13. 14. 15. 16. Oil vessel Non-return valve,1 bar Solenoid valve Nozzle, dia. 3.3 mm) Filter Heating cartridge Oil charging valve Oil level glass

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4. Technical Description

To be able to press the oil from the oil vessel, pos. 9, to the crankcase on the compressor, pos. A, which is working at the highest suction pressure PE+, the pipeline with the non-return valve (1 bar), pos. 10, is connected to the suction gas line for this compressor. There is a risk, however, that the differential pressure between the oil vessel, pos. 9, and the crankcase on compressor B may become so great that the oil conveyed via the solenoid valve 6a starts foaming. Usually, this foaming does not cause any problems as the oil is supplied to the compressor

above oil level. Any foaming that may occur will soon be dissolved in the crankcase. The system has one further advantage as the oil does not pass the level switch vessels 2a and 2b. Should foaming occur, this is not going to interfer with the working of the level switch. In case the oil return system is regulated by means of a float valve as described under System A, the same system as the one shown in Fig. 4.35 should be used.

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4. Technical Description

System C
System C is a float regulated oil return system which is used when only two compressors are operating in parallel with the same condenser. It is not a requirement that the suction pressure is the same on the two compressors. The float valve is of the same type as the one used in system A. The oil level equalizing system is illustrated in Fig. 4.35. It works by pressing the oil from one compressor to the next by means of the oil pump pressure (4.5 bar), pos. 3, in each of the compressors. Fig. 4.35 The oil level in the crankcase is regulated by a float valve, pos. 2a or 2b, which opens at a falling oil level in the compressor. If e.g. the oil level in compressor A is too low, the float valve, pos. 2a, will open. The oil pump in compressor B will now supply oil through the solenoid valve (nozzle incl.), pos. 1a, until a normal oil level has been established, whereupon the float valve will close. The solenoid valve pos. 1 is open when the compressor in question is running.

04 technical description.fm

3a
10/8

1a
10/8
SNV8 CD

2a

4a

3b

1b

2b

4b

1a - 1b: Solenoid valve 2a - 2b: Float valve 3a - 3b: Connection to oil pump discharge 4a - 4b: Standard oil return system

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4. Technical Description

Capacity Regulation of Compressor


All compressors have a built-in capacity regulating system which continually adjusts the compressor capacity to the cooling requirements of the plant. Even at reduced capacity the compressor works very efficiently. This makes it very well-suited for plants with reduced cooling requirements for lengthy operating periods. Fig. 4.36
13

Capacity Regulating Mechanism

sition and cannot be closed until the compressor is in operation and the oil pump has built up the oil pressure in the lubricating system. With an open suction valve there is no compression resistance in the compressor and this reduces its starting torque considerably. Thus, a motor dimensioned to suit the operating conditions of the compressor can easily start up the compressor also by using the star/delta starting system. For compressors fitted with extra capacity stages (extended unloading), one cylinder (SMC 104106-108) or two cylinders (SMC 112-116) will be in operation all the time, also at start up. See extended unloading.

Capacity Regulation and Unloading of Compressor


Capacity Regulation As mentioned in the introduction to this section all SMC and TSMC compressors are fitted with a hydraulic capacity regulating system by means of which the compressor capacity can be adjusted to the refrigerating requirements of the plant. When reducing the compressor capacity, two or more suction valves (on compressors with extended unloading: one or more suction valves) are forced open so that compression does not occur in the cylinders in question. The suction valve is forced open when the unloading ring together with the pins, pos. 19B, are pressed up under the suction valve, thus keeping the valve in open position as shown in Fig. 4.37.

The capacity regulating system including the frame, pos. 13, is activated by the compressor oil pressure and controlled by means of solenoid valves fitted on the compressor. At a capacity reduction two suction valves are forced open at a time. In this case no compression takes place in the relevant cylinders as the sucked in gas in the cylinders is pressed back to the suction chamber through the suction valves. The above forced opening of the suction valves is also used when starting up the compressor. The system works as follows: At compressor standstill all the suction valves are forced into an open po-

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4. Technical Description

Fig. 4.37

Cylinder Liner Complete

19F

The unloading frame, which is controlled by two brackets with guiding pins, does always activate two cylinders at a time. The unloading frame is moving back and forth by means of the unloading cylinder, pos. 12. If oil pressure is put on the cylinder during operation, the unloading frame will move to the left as shown in Fig. 4.38. Thus the angle of slope of the rocker arms is changed so that the unloading, ring pos. 19F, is able to move freely. Consequently, the cylinder is forced to work. If the oil pressure to the unloading cylinder closes, the unloading frame, pos. 13, will move to the right, thereby raising the rocker arms. The unloading ring with pins, pos. 19B, are pressed up under the ring plate and the suction valve is forced open, thereby unloading the cylinder. Fig. 4.38 Unloading System
15A 13 12 15B

19B

04 technical description.fm

19A

The unloading ring, pos. 19B, is activated by two rocker arms, pos. 15A, Fig. 4.38, one at each side of the cylinder liner. The rocker arms, which are placed in ball sockets, pos. 15B, are moved back and forth by the unloading frame, pos. 13.

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4. Technical Description

Start Unloading
As already mentioned the compressor cylinders are unloaded when there is no oil pressure on the unloading cylinders. This means that when the compressor is stopped, i.e. without any oil pressure, all the unloading cylinders are unloaded and consequently there is no compression resistance during start-up. This unloading during start-up reduces the starting torque of the compressor considerably. Fig. 4.39
12

This can be seen from the starting torque curves, in Section 6, Technical Data. Solenoid Valves for Capacity Regulation The unloading cylinders are controlled by solenoid valves, Fig. 4.39, which receive opening and closing signals from a connected regulator. This could e.g. be a programme device or the YORK electronic control system, UNISAB II, as described later in this section under Instrumentation.

3 1

The solenoid control valve is an electromagnetic three-way valve which, with a dead coil, connects the unloading cylinder, pos. 12, with the crankcase (the passage of the oil flow from pipe 2 to pipe 3 is open), Fig. 4.39 If the coil is energized, the valve will reverse so that the passage of the oil flow from oil discharge

pipe 1 to 2 is open and the connection to pipe 3 is closed. The solenoid valves are mounted in joint blocks, Fig. 4.40, with one, two, three or four solenoid valves in each block.

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4. Technical Description

Fig. 4.40

Solenoid Valve Block

04 technical description.fm

In the block there is a common supply of pressure oil from the oil pump (pipe a) to the solenoid valves as well as a common connection to the crankcase (pipe c). Each solenoid valve has its own oil connection to the relevant regulating cylinder (pipe b).

Standard compressors, however, with 2 cylinders on the SMC 104, 106 or 108 compressors or 4 cylinders on SMC 112 and 116 will be set to work when the compressor oil pump has worked up an oil pressure in the lubricating system. The cylinders mentioned are connected directly to the oil system without any solenoid valve as shown in . This makes it the lowest capacity stage on the compressors. The standard SMC 100 compressors can be regulated with the following capacity stages, represented by the hatched fields in Table 4.4.

Regulating Sequence
As described earlier, the compressors are always completely unloaded during start up exept for the compressor with extra capacity stages (extended unload), which will always have one or two cylinders loaded during start up (SMC104-108) and (SMC 112-116).

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4. Technical Description

Schematic Drawings, Standard

SMC/HP 104

SMC 112
5 2 1 1 3

TSMC 108 TSMC 188

% % 100 50 L Y
4

1 N

100

1 3

HP %
S S 1 2

S 2

83

67

2 2

100 67 33 0 L Y

SMC/HP 106 SMC 186


3

50 33
1 2

N Y

% 100 67 33 L Y 1 2 N

SMC 116

TSMC 116
%

% 100
1 1 3 5

1 5

100 83

2 1 2 5 S 1

S 5

SMC/HPC 108 SMC 188

87 75

67

% 100 75 50 25 L Y 1 2 3 N

4 2

1 3

63 50 37 25 L Y
2 2 4 6

6 8

50
S 3 3

4 S

33 L Y

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4. Technical Description

The electric regulating system should be made in such a way that, after start-up, additional capacity cannot be loaded until the motor has reached its full torque. The recommended run up time is 10 sec. The minimum speed according to the operating limit diagram is 5 sec (also applies to variable speed driven compressors). Fig. 4.41 illustrates the regulating system in principle. The percentages indicate the compressor capacity at every stage. When unloading a compressor without extra capacity stages, the solenoid valves are unloaded in numerical order: 1 -> 2 -> 3 -> 4. When loading, the order is: 4 -> 3 -> 2 -> 1. 04 technical description.fm Note: On TSMC 116 compressors the solenoid valves nos. 3 and 4 must always be loaded simultaneously as they control both the LP and the HP cylinders. Further, the TSMC compressors can, as standard equipment, be totally unloaded as described in the following. Total Unloading Besides the standard equipment as described in the previous passage the compressor can be fitted with a solenoid valve marked S (optional). Fig. 4.41. The TSMC compressors, however, are always equipped with this S solenoid valve.

The S solenoid valve makes the total unloading of the compressor possible - i.e. the compressor idles at 0% capacity. The S solenoid valve must never, however, be part of a normal capacity regulation as the compressor will heat up excessively during a lengthy operating period at 0% capacity. The S solenoid valve must therefore only be used as follows: When total unloading is required until the motor has reached its maximum torque moment. When a refrigeration plant has sudden brief operational stops for a short time and compressor stop is not required. In this case the compressor must not be allowed to run for more than 5 minutes at 0% capacity. If the compressor is equipped with a refrigerant cooled oil cooler type OOSI (R717) or OOKH (HFC/HFCF) and liquid refrigerants are available so that the cooling system can operate, idling is allowed for up to 30 minutes.

The regulating sequence can be seen from the schematic drawings in Fig. 4.41. Capacity Stages: The SMC 100 compressors can be regulated with the following capacity stages, represented by the hatched fields in Table 4.4.

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4. Technical Description

Fig. 4.41

Schematic drawings, Additional Equipment


SMC 188 Compressor seen from the shaft end
S 1

SMC/HPC 104

%
S

%
1

S S 1 2 3 2

1 3

100 50 0 L Y

Relief cylinder Oil return Oil pressure

100 75 50 25 0 L Y

SMC/HPC 106 SMC 186 SMC 112


S

SMC 116

% 100 67 33 0 L Y

1 S 1 2

%
S

A
S 3 1 S 5 1 3 5

% N 100

A
S 1 3

100 87 75

SMC/HPC 108

83 63 67
S 1 2 3 S 2 1 3

% 100 75 50 25 0 L Y N

B
S

B 50 33 0 L Y N
S 2 4

4 2

6 S

50 37 25 0 L Y N

2 4 6 S

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4. Technical Description

Table 4.4
Capacity per Stage in % 25 33 37 50 63 67 75 83 87 100

Compressor Type SMC 104 SMC 106 SMC 108 SMC 112 SMC 116 TSMC 108 TSMC 116

04 technical description.fm

As illustrated in Table 4.4, the SMC 100 standard compressors can only be capacity regulated in steps of two cylinders, which is sufficient in most cases. However, it will occasionally be required to feature more stages and for this reason a system called extended unloading has been developed to ca-

pacity regulate the compressor in steps of one cylinder per stage with the following capacity stages represented by the hatched fields in Table 4.5. Table 4.6 displays the numbers of the solenoid valves which must be activated to obtain the stated capacity stages (load).

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4. Technical Description

Table 4.5

Extended unloading

Base: Capacity step by one cylinder. For SMC 112 and SMC 116 min. load two cylinders. TSMC not included.

Type : SMC 100 Load 104 12.5% 16.7% 18.8% 25.0% 31.3% 33.3% 37.5% 41.7% 43.8% 50.0% 56.3% 58.3% 62.5% 66.7% 68.8% 75.0% 81.3% 83.3% 87.5% 91.7% 93.8% 100.0% 106 108 112 116

The system is optional and can be ordered when an order for a new compressor is placed. Already delivered SMC 100 compressors can be converted for extended or totally unloaded sys-

tems by means of reconstructing kits supplied by YORK Refrigeration's After Market Service Department.

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4. Technical Description

Extended unloading, solenoid valve no. according to Fig. 4.41 Table 4.6
Type : SMC 100 Load 104 12.5% 16.7% 18.8% 25.0% 31.3% 33.3% 37.5% 41.7% 43.8% S 3 4A 56B S 2 3S 4AB 56AB 456A 34B 23 2S 34AB 3456B 1 23S 234A 3456AB 23456A 12 123 1234B 123456B 1S 12S 123S 1234AB 123456AB 234AB 23456AB 456AB AB 6AB 0 S A 0 106 108 0 0 A AB 6A 112 116 0

04 technical description.fm

50.0% 56.3% 58.3% 62.5% 66.7% 68.8% 75.0% 81.3% 83.3% 87.5% 91.7% 93.8% 100.0%

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4. Technical Description

Extended Unloading The additional capacity stages are obtained by changing the unloading of one (SMC 104, 106 and 108) or two (SMC 112 and 116) cylinder pairs in such a way that the relief system only works the one cylinder while the other one is constantly connected. Note: When the mentioned systems are used, the compressor will not start up completely unloaded but with capacity as shown in Table 4.7. Table 4.7
104 25% 106 16.5% 108 12.5% 112 16.5% 116 12.5%

pos. 15D-1 and tand washer for bearing cup pos. 15E-1. The constantly connected cylinder is not mounted with unloading ring pos. 19B, washer pos. 19C-1, spring pos. 19D-1 and spring pos. 19E. It is marked S on the guide ring for the discharge valve pos. 19J-1. See the position of the cylinder in Fig. 4.43. Fig. 4.42
19J

Cylinder Liner with Suction Valve


S

The change is obtained by removing the following pos. nos. from the constantly connected cylinder: both systems of rocker arms pos. 15A-1, bearing cup pos. 15B-1, spring retainer pos. 15C-1, spring

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4. Technical Description

Fig. 4.43

Position of cylinders in compressor frame

8 6 4 3 2 5 S 4 1 5 S 6 3 7

4 3 S 1

SMC 104

SMC 106

SMC 108

16

12

S 7 6 5

4 3 2 1

04 technical description.fm

12 11 10

9 S 7

S 5 4

3 15 11 2 14 1 13 9 S

SMC112

S MC116

The valve body as for Total unloading is used to regulate the capacity stages instead of the standard valve body and the corresponding connecting pipes are mounted. The increased starting torque must therefore be taken into consideration when choosing motor and start system. For this purpose, the start up torque curves for R717 compressors and for HFC/HCFC compressors might be useful. These figures can be seen in Section 6, Technical Data, Starting torque of the

compressor. Please note that the max rpm is shown in the Operating Limits Diagrams in section 6. Please note that if the motor is started up by means of a Y/ starter, the starting torque of the compressor may exceed the starting torque of the motor at a high differential pressure. In these cases the compressor must be equipped with a by-pass system which makes the pressure on the discharge side of the compressor equivalent to the suction pressure as illustrated in Fig. 4.44.

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4. Technical Description

Fig. 4.44
Solenoid valve Nonreturn valve or automatically controlled stop valve

YORK Refrigeration's recommendations as to the cooling of the compressor. These recommendations can be found in the Operating Limits diagrams.

Variable speed drive (VSD)


Further, the compressor can be driven by VSD as long as the rpm limits are not exceeded - see Operating limits. For the standard and total unloading compressor, UNISAB II is able to control the VSD combined with the mechanical capacity control in the most efficient way taking into consideration both energy consumption and wear.

After long operating hours at minimum capacity, the temperature of the compressor block and the oil will exceed the normal operating temperatures. It is therefore recommended to adhere to

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4. Technical Description

Compressor Units
The compressor units can be delivered as standard units with base frames adapted to IEC electric motors. Against additional payment base frames can also be delivered for non-standard electric motors. On the base frame one oil separator can Fig. 4.45
SMC 100 Unit - Direct Couple SMC 100 Unit - V-belt Driven

be mounted for the SMC compressors and two oil separators for the TSMC compressors. Oil return from oil separator to compressor is controlled by a system as described in the section, Oil return to the compressor.

04 technical description.fm

The compressors can be connected to an electric driving motor or a combustion motor. The transmission can be either direct through a coupling that is flexible in both radial and longitudinal direction but which is also rigid in its contorsion, thereby stabilising the compressor rotation. The transmission can also take place by means of a V-belt drive, which, through the selection of standard belt pulley diameters, is able to provide the compressor with the correct number of revolutions and consequently, the desired compressor capacity. For more information, read Section 6, Technical Data. Please note that the compressor must be modified in order to change the direction of rotation: the oil pump must be changed on Mk4. Extent of Delivery The compressors can be delivered as blocks only in standard execution or mounted on a base

frame as standard units as illustrated on dimension sketches in Section 6, Technical Data, see also Dimension and Piping diagrams. Furthermore, it is possible to have compressors built into non-standard units following a specific agreement with YORK Refrigeration. A standard compressor is delivered without oil in the crankcase but charged with Nitrogen N2 to 0.2 bar [3 psi] overpressure. A yellow label, Fig. 4.46, on the compressor indicates this Nitrogen charge. Fig. 4.46
Pfyldt beskyttelsesgas Charged with inert gas Enthlt Schutzgas Charg du gaz protecteur Contiene gas protector N2 0,2 bar 3 PSI 1534-169

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4. Technical Description

Instrumentation
In the standard version the compressors are available with one of the following two systems: A: B: analogue reading and safety system UNISAB II reading, safety and capacity regulating system

In its standard execution the analogue system consists of controls, built onto the compressor on delivery, but without electrical connections. The controls are not factory adjusted and should therefore be adjusted before the initial start-up of the compressor. As may be seen from the drawing Fig. 4.47 some of the controls have a dual function, i.e. the type designation KP15 indicates that 1 is the low pressure and 5 the high pressure cut-out function. KP98 e.g. has two temperature systems incorporated. The specific controls are mentioned in the following, with reference to the numbers in Fig. 4.47. Fig. 4.47

The compressors are designed so that either the analogue system or the UNISAB II system can be fitted without changing the compressor. They each have their own characteristics, however, as described in the following: A: Analogue Reading and Safety System The analogue system only has reading and safety functions and cannot control the compressor capacity. Capacity control is handled by an external system built into the electrical switchboard and connected to the compressor on the mounting site. Some mounting costs must be expected. The control system can be one of many types and makes. It must, however, be able to send out opening and closing signals to the solenoid valves of the compressor in the prescribed unloading and loading sequence as already described in this section, Capacity Regulation and Unloading of Compressor. In special cases a manually operated switch system can be used instead of the automatic one. This makes it possible to regulate the compressor capacity by hand.

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4. Technical Description

1.

High Pressure Cut-out KP15 Adjusted to stop the compressor if the discharge pressure rises to a pressure 2 bar [29 psi] lower than the setting pressure of the by-pass valve. The pressostat has a manual reset function.

The pressostat has a manual reset function as well as a yellow indicator lamp which, when illuminated, indicates that the electric circuits are working. Normal oil pressure in the compressor is 4.5 bar [65 psi] which is indicated on the manometer 9 on Fig. 4.48. 5. Discharge Pipe Thermostat KP98 Adjusted to stop the compressor if the discharge gas temperature exceeds: 150 C [302 F] for R717 120 C [248 F] for HFC/HCFC This adjustment can, however, be set to 20C [68 F] above the normal discharge gas temperature, once this is known from experience. This makes it possible to safeguard the compressor against excessive temperatures. The thermostat has a manual reset function. 6. Oil Thermostat KP98 Adjusted to stop the compressor whenever the oil temperature in the crankcase exceeds 80C [176 F]. The thermostat has a manual reset function. 7. Oil Filter Differential Pressostat Indicates when oil filter pos. 9A needs to be replaced. Connections on the pressostat has a transparent housing and will indicate power supply with green LED and filter replacement with red LED.

2.

Low Pressure Cut-out KP15 Adjusted to stop the compressor if the suction pressure drops to a pressure corresponding to 5K lower than the lowest evaporating pressure. The pressostat has an automatic reset function

04 technical description.fm

and will therefore restart the compressor once the pressure rises again. 3. Intermediate Pressure Cut-out KP5 Used only on TSMC compressors. Stops the compressor if the intermediate pressure has risen to 8 bar [116 psi]. The pressostat has a manual reset function. 4. Oil Differential Cut-out MP55 Adjusted to stop the compressor if the pressure in the lubricating system drops below 3.5 bar [51 psi] compared to the pressure in the crankcase. The pressure cut-out has a built-in time delay of 60 sec. which keeps it idle during the start-up of the compressor until the correct oil pressure has been established.

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4. Technical Description

Manometers
For reciprocating compressors the following three types of manometers are available: Fig. 4.48
10 8-9

10.

Low Pressure and Oil Pressure Manometer Low pressure and oil pressure manometer indicating the compressor suction pressure and oil pressure in the lubricating system of the compressor. Used in the SMC and TSMC compressors. This manometer has two manometer works which are interconnected so that one of the works indicate the suction pressure with an arrow whereas the oil pressure is indicated by means of a dial in the middle of the manometer and turned round by the other works. The figure on the dial right below the arrow indicates the oil pressure. This makes it possible to read the oil pressure directly from the manometer. The manometers can be used with several refrigerants.

8.

High Pressure Manometer High pressure manometer indicating the discharge pressure of the compressor and used in SMC compressors. Fig. 4.48

9.

High and Intermediate Pressure Manometer High and intermediate pressure manometer indicating the discharge pressure for the HP and LP stages on TSMC compressors, Fig. 4.48. This manometer has two manometer works and two arrows, a red one for high pressure and a black one for intermediate pressure.

HFC/HCFC manometers for R22, R134a, R404A R717 manometers R410A, R744 (CO2) manometers On delivery of compressors using other refrigerants the manometers are graded for that particular refrigerant. The standard units on the scale is bar/C but others can be delivered on request.

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4. Technical Description

B: UNISAB II Reading, Safety and Capacity Regulating System UNISAB II is a computerized control and monitoring system which is specially developed to fit all YORK Refrigeration's SABROE reciprocating and screw compressors, i.e. the same UNISAB unit is used for both compressor types. It is only necessary to select type of compressor, refrigerant and a few other functions - and the UNISAB will be ready for operation. UNISAB II is based on YORK Refrigeration's extensive experience with design and operation of computerized compressor control systems. Fig. 4.49 04 technical description.fm Computerized Control and Monitoring

tion stops. In addition to efficient control and monitoring of single compressors UNISAB II is also designed for advanced control and monitoring of any combination of up to 14 compressors. It is thus possible to centrally control and monitor up to 14 compressors by using a COMSAB or PC COMSAB module. Multi-lingual System UNISAB II is available in 15 different languages, and it is possible to switch to the English version at any time. Easy to Operate UNISAB II has a systematic and easily accessible user interface which does not require any special knowledge or education. Operational data and status appear from the distinct display which features four lines with twenty characters each. The user interface also has arrow keys for menu selection, set key for parameter changing as well as keys for selection of manual/automatic operation, start/stop, manual capacity regulation and resetting.

UNISAB II is designed for safe control, monitoring and optimization of compressor operation and a minimum of unintended opera-

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Safety Monitoring and Control UNISAB II provides safe monitoring by means of warning and alarm values/settings for all measuring points. If a set value is exceeded, a red diode will flash slowly in warning situations without stopping the compressor, and quickly in alarm situations with compressor shut down. A display text will show the cause of the alarm. In both warning and alarm situations separate relays are activated for connection of a remote lamp, bell or alarm panel. It is easy to find all the set values and their warning and alarm values through the straightforward menu system. Besides monitoring the compressor pressures and temperatures, the UNISAB II also calculates the suction pressure vapour overheating, monitors the capacity slide position and oil flow, and calculates the oil filter differential pressure on screw compressors. For correct fault diagnosis in case of a compressor shut down, the UNISAB II immediately stores the alarm situations in its memory which can be displayed and analyzed on the display at any time. Instrumentation Depending on compressor type the UNISAB II is equipped with a number of

pressure and temperature transducers as well as position transmitters on the compressor. On one-stage reciprocating compressors three pressure and three temperature transducers are mounted while two-stage reciprocating compressors are equipped with four pressure and temperature transducers. Screw compressors are fitted with four pressure and three temperature transducers as well as one or two slide position transmitters. Furthermore, a thermistor input is available for motor protection. Factory Test Every UNISAB II is tested during the production process and when it is mounted on the compressor. A computer test is performed including a test certificate before the compressor leaves the factory. Please note that UNISAB II cannot directly combine the capacity of compressors with extended capacity control; only SMC 104 can be controlled directly by UNISAB II when it is equipped with a simple box (this has to be configured as a HPC 108 or SMC 108).

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4. Technical Description

Cooling of the Intermediate Discharge Gas on TSMC Compressors


At two-stage operation it is necessary to cool the discharge gas from the LP stage before it enters the HP stage. This intermediate cooling is carried out with the systems described below, depending on the type of refrigerant used. Common for these intermediate cooling systems is that they must cool the intermediate pressure gas sufficiently and at the same time ensure that no liquid is admitted into the HP stage since liquid may result in liquid slugging in the HP cylinders and excessive wear on the moving parts. It is therefore important to check the systems as described below. 04 technical description.fm Intermediate Cooling System with Intermediate Cooler Type DVEA, R717 The two-stage R717 plant may consist of two compressors, one low-pressure compressor (LP) and one high-pressure compressor (HP) as illustrated in Fig. 4.50 The plant may also consist of one or more two-stage compressors as shown in Fig. 4.51. In both cases the compressors are connected to an intermediate cooler in which the warm gas from the LP-stage is cooled down before it flows on to the HP-stage. In the intermediate cooler the liquid level of R717 is regulated by the float valve and the discharge gas from the LP stage is cooled by bubbling up through the refrigerant from the distributor at the bottom of the intermediate cooler.

Fig. 4.50

SMC 100 compressor


Oil separator
CT

Oil separator

Equalizing pipe
IP HP

LP

IP

Mixing chamber HP Solenoid valve

LP Float valve Intermediate cooler type DVEA Liquid subcooling spiral Oil drain off

Fig. 4.51

TSMC 100 Compressor


Oil separator Oil separator

CT LP
IP LP HP IP

Mixing chamber

Equalizing pipe Solenoid valve Intermediate cooler Float valve

Liquid subcooling spiral Oil drain off

In the liquid subcooling spiral the refrigerant flowing from the receiver to the evaporator in the refrigeration plant is cooled. The intermediate cooler is dimensioned so that the cooled gas is free of liquid refrigerant before leaving the top of the intermediate cooler. It is important to check that the float valve is operating correctly and keeping the liquid level constant. Frosting of the liquid level pipe on the intermediate cooler indicates the liquid level.

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As a matter of precaution a solenoid valve should be used in the liquid line to the float so that it may shut off the liquid flow to the intermediate cooler whenever the system is stopped. At regular intervals the intermediate cooler must be drained of oil through the oil drain valve. Intermediate Cooling System with Liquid Injection into the Intermediate Discharge Gas, R22 and R717 Two-stage compressors type TSMC can be equipped with a pipe connection from the LP stage discharge branch to the HP stage suction branch as shown in Fig. 4.52. In the pipe connection the warm discharge gas from the LP stage is cooled by injection of liquid refrigerant into the intermediate pipe. This can be achieved with the following two systems: 1. Intermediate Cooling with Thermostatic Expansion Valve Type: TEA (R717) or TEX (R22)
TSMC
Oil separator

Connection, pos. B, pipe dimension OD 10 mm, emerges from receiver or priority vessel as described in Cooling with thermopump - R717 later in this section. The intermediate discharge pipe is built onto the compressor on delivery as a block or a unit. On delivery of a compressor block the liquid system including the expansion valve must be mounted on site. 2. Intermediate Cooling with Thermostatic Injection Valve Type: TEAT (HCFC)

The intermediate cooling system is designed as illustrated in Fig. 4.53. Here the intermediate cooling is carried out by a thermostatic injection valve of the TEAT type and the subcooling takes place in a HESI heat exchanger. Fig. 4.53
KP 77

T
Oil separator CT LP
IP HP LP IP

Fig. 4.52

Mixing chamber

LP CT LP From receiver Mixing chamber Opt HESI A TEAT Liquid supply To evaporator

B
TEA or TEX Solenoid valve Stop valve Filter

In the system in Fig. 4.52 the liquid refrigerant conveyed to the intermediate pipe is regulated by a thermostatic expansion valve type TEA (R717) or TEX (R22) with a sensor placed on the intermediate pipe close to the HP stage.

The sensor of the TEAT valve is placed in a sensor pocket at the HP discharge branch of the compressor, and a proper thermal contact is obtained by means of the heat conducting compound. The solenoid valve is opened by the KP77 thermostat whenever the temperature of the pressure pipe exceeds 55C [131F].

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Automatic Regulation of Intermediate Pressure IP


In two-stage plants with reciprocating compressors it should be pointed out that the intermediate pressure is not allowed to drop excessively. A low intermediate pressure reduces the damping effect of the gas on the valve plates in the LP stage discharge valves. The danger is that a breakdown may occur in the form of broken valve plates. In order to prevent this it may be necessary to mount a by-pass system between the HP side and IP side. Thus a suitable amount of gas is led back to the IP side. The system is illustrated in Fig. 4.54. 04 technical description.fm The lower limits for IP have been fixed at: -15C [5F] for R717 plants - 25C [-13F] for HFC and HCFC plants. The by-pass system is additional equipment and is usually mounted by YORK Refrigeration directly on the internal pipe connections on the compressor block . The diagrams, Fig. 4.50 to Fig. 4.53, do only show the principle of the different systems and must not, therefore, be used directly. Fig. 4.54
TSMC
PM main valve CVC pilot valve -0.75 -> 7 bar Oil separator

Determining the Intermediate Pressure IP


The intermediate discharge temperature of the compressor is dependent on the evaporating temperature ET, the condensing temperature CT and of the ratio between the capacity at the LP and HP stages, corres-ponding to the number of cylinders that is working at each stage. If a TSMC compressor is working at 100% capacity, the ratio between the number of cylinders is 3:1 as indicated in the Table 4.8. When unloading the cylinders, this ratio is changed to 2:1 or 1:1 and the intermediate pressure will drop accordingly. The intermediate discharge pressure is determined by entering the suction tempera-ture ET and the condensing temperature CT into the calculation programme COMP 1. The lower limits for the intermediate discharge pressure are the same as stated above: -15C [5F] for R717 plants and -25C [-13F] for HFC and HCFC plants. To ensure correct operating conditions all partial load possibilities must be calculated. If the result of the calculation shows values below the stated limits, a by-pass must be fitted as described above. However, it is also possible to connect the capacity regulating system in such a way that the compressor cannot operate at the capacity stages which produce suction temperatures lower than the limiting value of the refrigerant in question. As described in the section Capacity regulation the TSMC compressors can be capacity regulated at the following stages:

LP

IP HP LP LP

LP Opt. B

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Table 4.8
Compressor Type Capacity % LP TSMC 108 100 66 33 100 83 67 50 33 6 4 2 12 10 8 6 4 Number of Cylinders Working HP 2 2 2 4 4 4 2 2 3:1 2:1 1:1 3:1 2.5:1 2:1 3:1 2:1 Ratios

TSMC 116

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4. Technical Description

Cooling Systems for Compressors


To preserve the optimum lubricating capacity of the oil it may become necessary to cool during compressor operation. Depending on the operating conditions and the type of refrigerant the plant uses, a number of cooling systems are available. See Section 6, Technical Data, Operating Limits Diagrams. The following standard cooling systems can be delivered for the compressors, depending on which type of refrigerant the compressor is operating with as well as the compressor type itself.

lease any surplus heat in the compressor into the environment, see Fig. 4.55 and Fig. 4.56. Fig. 4.55 Air-cooled Top Cover

Fig. 4.56

Air-cooled Side Cover

Standard Cooling Systems for Compressors


04 technical description.fm 1. R717 a. SMC only: Air-cooled top and side covers and refrigerant-cooled oil cooler. Water-cooled top and side covers. SMC only: Compressor cooling with thermopump

There is therefore no need for forced cooling air flow past the covers. It is, however, necessary to cool the oil in the compressor by means of a built-in oil cooler, which is cooled by the refrigerant in the plant. The cooling system is built onto the compressor. It operates as illustrated in piping diagram, Fig. 4.57, for a normal one-stage compressor and in Fig. 4.58 for a booster compressor. The cooling system consists of an oil cooler mounted on the oil pipe which connects the oil pump with the shaft seal. The oil cooler is dimensioned to maintain the oil temperature at 50-70C [122 - 158 F]. The expanding gas is led through pipe, pos. 1, Fig. 4.57, to the compressor suction side. On the outside of the pipe the sensor for the thermostatic expansion valve, type TEA, is fitted.

b. c. 2.

R22-R134a-R404A-R507-R410A-R744 a. b. c. Air-cooled top and side covers. Air-cooled top covers and water-cooled side covers. Air-cooled top and side covers and refrigerant-cooled oil cooler.

Description
1a: Air-cooled Top and Side Covers with Refrigerant-cooled Oil Cooler R717 Air-cooled top and side covers are covers without cooling fins, but with a surface large enough to re-

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The expansion valve, type TEA, is particularly suited for R717. In the liquid line there is also a solenoid valve which closes when the compressor is stopped. Fig. 4.57 Normal One-stage Compressor R717
T
Oil separator

LP

HP LP

The pipe pos. 1 on the booster and two-stage compressor is led to the IP side as illustrated in Fig. 4.58 and Fig. 4.59. Thus the compressor capacity is not affected by the oil cooling system. The liquid supply is regulated by a thermostatic injection valve of the TEAT type whose sensor is placed on the discharge pipe of the compressor. This gives the cooling system two cooling functions. One is to cool the oil in the crankcase the other to cool the discharge gas and consequently the discharge side of the compressor. Fig. 4.58 Booster Compressor R717

T
Liquid from receiver Oil cooler TEA Solenoid valve Filter Stopvalve LP IP Oil separator

The filter filters off any dirt particles in the liquid. The filter element can be removed and cleaned. The stop valve can block the cooling system from the refrigeration plant. A thermostat T is connected to the cooling system and its sensor is placed in the oil of the crankcase. The thermostat is set to open the solenoid valve whenever the oil temperature exceeds 55C [131 F]. In this way it is made sure that the oil heats up quickly and separates as much refrigerant as possible. UNISAB II controls the solenoid valve directly based on the measured oil temperature. Booster Compressor As illustrated in Fig. 4.57, the pipe pos. 1 is taken to the LP side of the compressor. This means that the compressor must compress the gas coming from the oil cooler which makes up only a very small part of the compressor capacity.

Liquid from receiver Oil cooler TEAT Filter Stopvalve Solenoid valve

Fig. 4.59
Oil Separator

Two-stage TSMC Compressor R717


IP HP Oil Separator

LP 1

IP HP LP IP

IP

Liquid from receiver Stop valve Filter

TEAT Solenoid valve

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The TEAT valve is set to inject liquid into the compression chamber of the compressor via the oil cooler in order for the discharge gas to maintain a temperature between +55 and 95C [131 F and 203 F]. The diagrams, Fig. 4.57 to Fig. 4.59, do only show the principle of the different systems and must not be used directly. 1b: Water-cooled Top and Side Covers - R717 The water cooling system must cool the entire compressor block. In principle, it consists of plane covers which are fixed on the top and side covers with a gasket in between as shown in Fig. 4.60 and Fig. 4.61. A system of canals is thus created between the two covers in which the water is distributed evenly and cools effectively. As the water covers can be dismantled without removing the top covers and depressurizing the compressor, the pipe system and the inner faces of the water cover can easily be cleaned of any impurities. It is fairly easy to build this water cooling system on an air-cooled compressor. Note, however, that the air-cooled side covers must be replaced with covers with cooling fins on the inside. This may be seen by comparing Fig. 4.56 with Fig. 4.61.

Fig. 4.60

Water-cooled Top Cover

Note: Do not use sea water as cooling water on top covers. Fig. 4.61 Water-cooled Side Cover

04 technical description.fm

Mounting of Cooling Water Hoses


On delivery of the compressor, the cooling water covers are mounted, but they are not connected with water hoses. These are delivered separately to avoid damaging the hoses and connecting branches during transportation and mounting. The cooling water hoses are mounted as shown in the drawing which is delivered with the compressor. A copy of this drawing can be seen in Fig. 4.62.

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Fig. 4.62

Mounting of water hoses on top and side covers.

Cooling of top and side covers SMC 104-106-108 and TSMC 108
SMC 104 3185-230
4 5

Pos. No. Hose Type L (mm) 1 2


3

C C C C A SMC 106 3185-231

715 115 505 645 835

3 4 5

3 2 1

Pos. No. Hose Type L (mm)


5

1
4

C C D C C C

730 125 335 375 515 1100

2
6 3 3 2 1

3 4 5 6

SMC 108 TSMC 108 3185-232 Pos. No. Hose Type


4 4

L (mm) 760 150 340 255 230 1090

1 2 3 4

C C C E C A

3 3 2 1

5 6

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Fig. 4.63 Cooling of side covers only SMC 104-106-108-112-116 and TSMC 108-116
Side covers 3185-235 SMC 104106-108 and TSMC 108 Pos. No. 1 2 3 4 Hose Type C C C C L (mm) 715 175 230 765

Side covers SMC 112 3185-246


3 4 1

Pos. No. Hose Type 1 2 3 4 A A C A

L (mm) SMC 112 750 130 750 220

04 technical description.fm

Side covers 3185-236 SMC 116 and TSMC 116


3 3 3 3

Pos. No

Hose Type

L (mm) SMC 116 TSMC 116 740 160 770 215

1
4 2 1 1

A A C B

2 3 4

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Fig. 4.64 Cooling of top and side covers SMC 186-188 and TSMC 188
SMC 186 3185-242
5 4

Pos. no. 1 2 3

Hose type C C C C C C

L (mm) 815 1830 605 245 1165 595

6 3 3 2 1

4 5 6

5 4 4

SMC 188/TSMC 188 3185-243 Pos. no. 1 2 3 E A C C C C Hose type L (mm) 335 1755 535 245 1175 340

3 3 2 1

4 5 6

Side covers only 3185-244 Pos. no. 1 2 3 4


3 4 1

Hose type C C C C

L (mm) 1165 245 1315 410

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Note: The direction of the water flow is indicated in Fig. 4.62. The hose sections have been shortened to the lengths indicated from factory. In the supply pipe to the water system a solenoid valve must be fitted which shuts off the water flow in the refrigerating system when the compressor is not in operation. It is recommended, however, to continue the water cooling for approx. 10 minutes after the compressor has been stopped to protect the cooling water hoses against excessive temperatures. Dimensions of the inlet and outlet pipes for the cooling water system are indicated in Section 5, Physical and Connection Data Table of Water Connection.

Necessary Water Consumption To achieve satisfactory distribution of cooling water and hence proper compressor cooling, the following limiting values should be followed. Min. Water Flow 5.5 litres per hour per kW motor output. On water circulation plants greater water flow is recommended. See Fig. 4.65. Max. permissible inlet temperature: +40C [104F] Min. permissible inlet temperature: +10C [50F] Max. permissible outlet temperature: +55C [151F] Max. permissible temperature rise from inlet to outlet on compressor: 15C [59F] Max. permissible cooling water pressure: 8 bar.

04 technical description.fm

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4. Technical Description

Pressure Loss in the Cooling System in SMC/TSMC Compressors


Totally for Side and Top Covers Fig. 4.65 Pressure loss diagram
Pressure loss p(mWc) TSMC 108 SMC 108 SMC 106 SMC 104

Fresh ground water Water from cooling towers or condensers Closed water systems in which the water is cooled and recirculated
SMC 112 T/SMC

Salt water (Brine) Note: Do not use sea water as cooling water on top covers. Obviously, it is very important that the water does not cause algae to grow or calcareous deposits to develop in the cooling system. This means that when water is recirculated in a closed system, a water treatment plant will usually be required. In such cases YORK Refrigeration recommends that a local dealer in water treatment plants be contacted.

116

SMC 186 T/SMC 188

100

500

1000

Volumetric flow V(l/hour)

Water Quality Water that can be used as cooling water: Water from the water works or sea water

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4. Technical Description

1c: Cooling with Thermo Pump - R717


The thermo pump is a compressor cooling system which makes the compressor completely independent of the cooling water. The system is therefore very applicable in areas where there is a shortage of water resources or where the water quality is poor. The thermo pump system can only be used with R717. The purpose of the thermo pump is both to cool the oil in the crankcase and to cool the compressor discharge gas in order to lower the temperature in the whole compressor. Fig. 4.66 Short Block with Thermopump

On TSMC compressors cooling only takes place in the high pressure stage top covers and no oil cooler is used in the crankcase. The thermo pump works under the influence of heat coming from the oil in the crankcase. In this way it also regulates its own pump capacity. This means that the thermo pump works slowly when the oil is cold, e.g. right after start-up of the compressor, but as the oil temperature gradually rises, the pump capacity will increase accordingly. The thermo pump does not start, however, until the discharge gas temperature exceeds 80C [176 F]. The pumping cycle of the thermo pump, i.e. a filling and an evacuation period, lasts between 4 and 8 minutes depending on the number of cylinders of the compressor, its capacity, the oil temperature in the crankcase and the operating pressure and temperatures of the plant. The filling period takes about 45 sec.

04 technical description.fm

The thermo pump is mounted as a side cover on the compressor and works by pressing the refrigerant into the canal system on the top covers and into the oil cooler which - depending on the operating conditions - is built into the crankcase.

The thermo pump has an important advantage, namely that the refrigerant pumped by the thermo pump is led directly into the discharge gas of the compressor. Consequently, this will have no influence on the compressor capacity.

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4. Technical Description

The Structure of the Thermo Pump The side cover, see Fig. 4.67 pos. 98A, together with the cooling cover, pos. 98Q, constitute a pump vessel, pos. 98, which is supplied with heat Fig. 4.67 Side Cover with Thermo Pump
98G 98D B 98B 98A

from the oil bath in the crankcase. The cooling cover is equipped with cooling fins in order to ensure a proper thermal contact with the oil.

A 98Q C

98H 98X

98C

As indicated in the principle drawings of the SMC 108,Fig. 4.68, and a TSMC, Fig. 4.69, the thermo pump has the following connections: Connection pos. A, which is linked to the compressor suction side and which can be blocked by means of solenoid valve pos. 98G, is used to lower the pressure in the pump vessel, pos. 98. This is part of the pumping cycle.

Connection pos. B emerges from the plant receiver or the priority tank (will be described later) and goes right to the valve block pos. 80. Connection pos. C is connected to the bottom of the pump vessel pos. 98 as well as to the top covers and the oil cooler pos. 98T through a number of nozzles, pos. 98M.

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Fig. 4.68

SMC 108
98U

98M 98M 4 2 98T 98

98M 98Z HP LP 3 98G 98B 98M 98H

98X

Filling and evacuation of the pump vessel is controlled by two level sensors, pos. 98C, Fig. 4.67. By means of the control box, pos. 98B, the sensors control the solenoid valves, pos. 98G and pos. 98H, so that they open and close simultaneously. The thermo pump is safeguarded by the following systems as shown in Fig. 4.67, Fig. 4.68 and Fig. 4.69: a. A thermostat built into the control box pos. 98B with sensors pos. 98X fitted on the compressor discharge pipe. The thermostat is factory set to start up the thermo pump once the discharge gas temperature is above 80C [176 F]. b. An evacuation system emptying the pump vessel through solenoid valve pos. 98V whenever the thermo pump stops. Please, note that the pipe connection pos. D to the plant evaporating side must be at a place where there is suction pressure and no risk of the liquid flowing back to the compressor through the suction line. Connection should e.g. be made to the liquid separator or the evaporator. c. A safety circuit with a non-return valve, pos. 98Z, which opens for the flow in the pump vessel at a pressure 3 bar [44 psi] higher than the one in the compressor discharge gas line.

B 98K 80 D 98K 98V 98Y

04 technical description.fm

Fig. 4.69

TSMC 108
98M

98Z HP S

S IP 2 98G 98B 98 98X

98H B 80 D C 98K 98K 98V 98Y

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4. Technical Description

Description of the Pumping Cycle


Filling the Pump Vessel As soon as the liquid leaves the bottom level sensor, the control box will activate the solenoid valves pos. 98H in valve block pos. 80 and pos. 98G. Thus solenoid valve, pos. 98G, opens in the pipe connection to the compressor suction side and the pressure in the pump vessel decreases slightly. At the same time solenoid valve pos. 98H opens and refrigerant liquid starts flowing to the pump vessel through pipe connection B. Emptying the Pump Vessel When the top sensor, pos. 98C, has registered that the liquid has reached the top level, both solenoid valves will be closed by the control box. The pressure in the pump vessel will now rise as a consequence of the heat impact from the compressor oil and will - when it exceeds the pressure on the compressor discharge side - make the refrigerant flow through the pipe connection C to the top covers and the oil cooler. At the top covers the refrigerant expands through the nozzles, pos. 98M, directly into the hot discharge gas, resulting in immediate cooling of the discharge gas. The oil cooler OOSI (not always required) is a heat exchanger in which the expanding refrigerant

- after cooling of the oil - is taken to the compressor discharge side. Once the liquid in the pump vessel has returned to its lowest level, it is registered by the bottom sensor and the control box opens the two solenoid valves for a new pumping cycle. Capacity Regulation of Thermo Pump When reducing the compressor capacity, it will be necessary to reduce the cooling effect of the thermo pump as well. This is done as follows: SMC 104-106-108, TSMC 116 The pipe connection from the pump vessel to the top covers is divided into two pipe lines. In one of these pipe lines a solenoid valve, pos. 98U, is fitted. This solenoid valve is wired to the capacity regulating system of the compressor and it closes when the compressor capacity has been reduced as indicated in the following table, Table 4.9. Table 4.9
Compressor Capacity SMC 104 SMC 106 SMC 108 TSMC 116 Solenoid Valve pos. 98U Open 100% 100 - 67% 100 - 75% 100 - 83 - 67% Closed 50% 33% 50 - 25% 50 - 33%

On the SMC 112-116 two thermo pumps have been mounted as shown in the principle drawings Fig. 4.70, Fig. 4.71 and Fig. 4.72.

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4. Technical Description

Fig. 4.70
98M

SMC 112
98M 4 2 LP 6 98M 98Z A 98G X 98B 98 98H 98K 98D 98K 98V 98Y 98M

Fig. 4.71
98M

SMC 116
98M 98M 4 2 LP 6 8 98M 98Z A 98G X 98B 98

98H 98K 98D 98M 98M 98M HP 98G 98B B 98M 98H 98K
B

98M

98M

98M

3 7 1 98T

LP 98 5

B 1

3 LP 5

98Z A 98B

04 technical description.fm

98K 80 D

B 98H

98V 98Y

98

Fig. 4.72
98K 80 D 98K 98V 98Y C 98M

TSMC 116
98M

S HP 3

4 IP S A 98G 98B 98

98H 98K C B 98D 98K 98V 98Y

98U

1 98T

98M

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4. Technical Description

The total capacity of the thermo pumps is adapted to the compressor capacity by stopping and starting the thermo pump marked with an X on the principle drawing. The stopping and starting is achieved through the wire connection of the thermo pump via terminals 5 and 6/7 or 8 to the capacity regulating system of the compressor. The supply voltage to the thermo pump must be switched off once the compressor capacity has been reduced to the values indicated in the Table 4.10. Table 4.10
Compr. Capacity Thermo Pump at Compressor Shaft End Working SMC 112 SMC 116 100 - 83 - 67% 100-87-75-63% Not Working 50 - 33% 50 - 37 - 25%

side of the plant. See the previously mentioned point b.

Ensuring Liquid to the Thermo Pump


The thermo pump must always be ensured liquid from the plant, irrespective of whether the plant lacks liquid or if some other factor prevails. Thus, the thermo pump must also be ensured liquid during a possible pump down by means of the compressor. In other words: During operation the compressor must never be short of cooling. This safety is achieved either by taking the liquid directly from the receiver, pipe connection B, or by building a priority tank into the liquid line of the plant, Fig. 4.73. The liquid volume A of the priority vessel must be minimum 10 litres per thermo pump. The liquid tube from the priority vessel to the thermo pump must be dimensioned to prevent the formation of flash gas along the way.

When the compressor is stopped, the current to the thermo pump is cut off, closing the solenoid valves pos. 98H and pos. 98G. At the same time solenoid valve pos. 98V opens and drains the liquid in the thermo pump back to the evaporating

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4. Technical Description

Fig. 4.73
1 1

Receiver

3 B B 2

1: 2: 3: B:

Refrigerant liquid from condenser/receiver Refrigerant liquid to evaporator Refrigerant liquid reserve for oil cooling Refrigerant liquid for oil cooling

04 technical description.fm

Power Connection
The control box is geared for the 3 voltages listed below. Voltages: 110V - 50/60Hz 220V - 50/60Hz 240V - 50Hz The control box contains a terminal strip as shown in Fig. 4.74.

Fig. 4.74
K1

Terminal 1

K3 Terminal 2 PT100 sensor M1 Terminal 1 Terminal 4 GND K2 GND Upper level sensor GND Terminal 1 Lower level sensor L N N M2 N

Terminal 2

Main voltage selector VS1


230 115

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4. Technical Description

2a: Air-Cooled Top and Side Covers R22 - R134a - R404A - R507 Use the same cover mounting as described in paragraph 1a. As indicated in the Operating Limits Diagrams in Section 6, Technical Data, there is no need for oil cooling. 2b: Air-Cooled Top Covers and Water Cooled Side Covers R22 - R134a - R404A - R507 If water is available and a need for cooling exists according to the Operating Limits Diagrams, Section 6, Technical Data, this system is an excellent solution. The water-cooled side covers are mounted as described in paragraph 1b, Fig. 4.63. Fig. 4.75 Cooling of Side Covers only

Table 4.11
Pos No 1 2 3 4 Hose type C C C C Length (mm) 715 175 230 765

2c: Air-Cooled Top and Side Covers and Refrigerant-Cooled Oil Cooler R22 - R134a - R404A - R507 Use the same cover mounting as the one described in paragraph 1a. In principle, the oil cooling system is constructed as illustrated in Fig. 4.57 for one-stage compressors, in Fig. 4.58 for booster compressors and in Fig. 4.59 for two-stage compressors.

3 4 1

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4. Technical Description

fCompressor Accessories

Following an order, the accessories listed below can be delivered for compressors or units: Explosion-proof instrumentation instead of the standard equipment. Explosion-proof heating cartridge for oil heating in the crankcase. Explosion-proof solenoid valves for capacity regulation. Vibration dampers to be inserted between unit and machine floor dimensioned to fit the unit in question. Normal set of tools, comprising special tools for dismantling and assembling the compressor.

Extended set of tools. Besides the normal set of tools, this set contains all necessary standard hand tools. Spare parts set in various sizes. When servicing compressor and unit, it is always an advantage if you, as our customer, have some of the most commonly used spare parts at your disposal. This enables you or a summoned YORK Refrigeration service engineer to carry out the necessary service work without having to spend extra time on getting the spare parts required. Spare parts can be delivered as described in the following. When contacting the local YORK Refrigeration representative, it is possible to receive a list of the spare part sets recommended by YORK Refrigeration.

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4. Technical Description

Types of Spare Parts Set:


For the different compressor blocks: Standard spare parts set: Contains a suitable selection of O-rings as well as valve ring plates and valve spring. Extended spare parts set: In addition to the parts included in the standard spare parts set, the set contains a cylinder liner and discharge valve as well as an extended number and types of gaskets and fittings. Certificate spare parts set: In addition to the parts from the extended spare parts set this set contains a major number of components and wearing parts selected by the classification societies.

Special spare parts set: This is a more comprehensive set than the extended spare parts set as almost all O-rings and gaskets are included and for the most wearing parts the number of parts have been extended.

For the Different Compressor Units: Standard spare parts set: This is a set consisting mainly of O-rings and gaskets for some of the components included in the unit. Certificate spare parts set: In addition to the parts from the standard spare parts set this set contains other components selected in accordance with the requirements of the classification societies.

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5. Physical and Connection Data

5. Physical and Connection Data


The purpose of this document is: to describe the physical data of the equipment, to give complete information concerning the requirements of the surrounding system. jury to personnel. It may also cause damage to or destruction of the equipment.

Safety Precautions
In addition to the safety precautions mentioned in Section 3, Safety Precautions, the following apply to the connection of the unit: The pipe dimensions on the connections made for the unit must fit the dimensions of the connection place. Moreover, the pipes must be of a type and dimension approved for the maximum pressure of the plant. When planning the pipe layout, make sure that it complies with prevailing standards regarding pipe bend, flange design, etc. Electrical connection must be carried out so that it complies with current legislation within the area in question. Electric cables must be dimensioned on the basis of the maximum power consumption of the plant. The cabling must be made so that the cables do not touch any moving parts. It is recommended to place the cables in cable trays.

The safety precautions are intended for all user categories. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

05 physical and connection data.fm

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or in-

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5. Physical and Connection Data

Physical Data
Dimension Sketches Dimension sketches of all compressor blocks and units are included in a separate binder Dimensions and Piping Diagrams. tion is welded on the connecting branch of the valve. See Table 5.1 Note: Be aware of the measures which must be taken in order to avoid damaging the valve and other parts of the unit when welding. See Section 7, Installation Instructions. Connections to the Compressor The tables in Table 5.1 and Table 5.2 show the pipe connection on standard compressors. On delivery from YORK Refrigeration the compressors are fitted with standard welding nipples on suction as well as discharge side. The tables Table 5.3 to Table 5.5 include a list of applicable welding nipples. The table Table 5.6 show the possible connections of the compressor. In the table some of the connections are marked plugged, which means that the thread hole is closed by means of a plug and a gasket.

Connection Data
Refrigerant Suction Side On the compressor suction side the pipe connection is made to the stop valve pos. 1 - see Dimensions and Piping Diagrams. The pipe connection is welded on the connecting branch of the valve, see Table 5.1. Note: Be aware of the measures which must be taken in order to avoid damaging the valve and other parts of the unit when welding. See Section 7, Installation Instructions. Refrigerant Discharge Side On the compressor discharge side the pipe connection is made to the stop valve pos. 2 - see Dimensions and Piping Diagrams. The pipe connec-

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5. Physical and Connection Data

Table 5.1
Nominal diameters DN for standard welding connections (in mm) Suction Compressor Conn. SABR. type SMC 104 SMC 106 SMC 108 TSMC 108 SMC 112 SMC 116 TSMC 116 129.5 65 80 80 80 125 125 125 80 100 100 100 125 125 125 Conn. SABR. type 90.5 90.5 90.5 F 129.5 129.5 90.5 65 65 65 50 100 100 65 65 65 65 50 100 100 65 Conn. SABR. type 90.5 65 65 Conn. SABR. type FS 50 50 Discharge Interstage LPD+) Interstage HPS+) Oil Separator Conn. SABR. type FP 65 65 65 65/50 ++) 100 100 100/ 65++)

154.5

129.5

100

100

FS

80

80

FP

Table 5.2
Nominal diameters for standard welding connections (in inch.)

05 physical and connection data.fm

Suction Compressor Conn. SABR. type SMC 104 SMC 106 SMC 108 TSMC 108 SMC 112 SMC 116 TSMC 116 129.5 2 1/2" 3" 3" 3" 5" 5" 5" 3" 4" 4" 4" 5" 5" 5" Conn. SABR. type 90.5 90.5 90.5 F 129.5 129.5 90.5

Discharge

Interstage LPD+) Conn. SABR. type

Interstage HPS+) Conn. SABR. type

Oil Separator Conn. SABR. type

2 1/2" 2 1/2" 2 1/2" 2" 4" 4" 2 1/2"

2 1/2" 2 1/2" 2 1/2" 2" 4" 4" 2 1/2"

90.5

2 1/2"

2 1/2"

FS

2"

2"

FP

2 1/2" 2 1/2" 2 1/2" 2 1/2" /2"++) 4" 4" 4"/ 2 1/2" ++)

154.5

129.5

4"

4"

FS

3"

3"

FP

Table 5.3
Available Welding Connections Connec. type 90.5 129.5 154.5 219.5 Pipe type 32 R-KB ANSI R-KB ANSI R-KB ANSI R-KB ANSI 095 122 Nominal Diameters for Welding Connections, Sabroe part no. 2322-1) 40 100 124 50 102 126 65 102 127 105 129 107 131 108 132 109 133 110 134 111 135 80 100 125 150

1)

Example: Connection type R-KB-32, part no. 2322-095

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5. Physical and Connection Data

+) ++)

HPS: High pressure suction side PD: Low pressure discharge side The first value: connection for the low pressure Oil Separator. The second value: connection for the high pressure Oil Separator. Fixed connection Fixed connection, delivered separately

FP

Fixed pipe

R-KB Boiler pipe according to DIN 2448 ANSI Pipe according to ANSI B31.5 schedule 80 and 40 (DN 32 and 40 ~ schedule 40). Note: In this connection two types of standard welding nipples are available. This should be specified when ordering.

F FS

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5. Physical and Connection Data

Standard welding nipples are available from YORK Refrigeration under the designation of RKB nipples, following the standard of DIN 2448 and with pipe dimensions as indicated in the table in Fig. 5.1 (OD, s, ID1). The welding nipples are universal as their welded ends have dimensions according to DIN 2448.

If you wish to connect the welding nipples to a pipe with a thicker wall, the nipples can be shortened and thus the internal diameter is reduced and the wall thickness increased as illustrated in Fig. 5.1. This makes it possible also to use the welding nipples for pipes in due form according to ANSI B31.5, schedule 80 and 40.

Fig. 5.1

Welding Nipples for R-KB Pipes

305

1
05 physical and connection data.fm

OD1 OD ID1 155 S L A


Table 5.4

OD2

ID2

ID3 ID2

Standard welding end for R-KB pipes according to DIN 2448 INCH 2" 2 1/2" 2 1/2" 3" 4" 5" DN 50 65 65 80 100 125 OD 60.3 76.1 76.1 88.9 114.3 139.7 s 2.9 2.9 2.9 3.2 3.6 4.0 ID1 54.5 70.3 70.3 82.5 107.1 131.7 OD1 76.0 76.1 113.5 113.5 114.3 144.0 OD2 90.5 90.5 129.5 129.5 129.5 154.5

1) ID 2 52.5 62.7 62.7 77.9 102.3 128.1 ID3 57.0 57.0 93.0 93.0 93.0 125.0 A 55 65 75 70 65 80 L 4.0 14.0 14.0 9.0 9.0 7.0 Mat. 2 2 1 2 2 2

1) Smallest inner diameter = ANSI B31.5 Material: 1: RST 37-2 DIN 17100 2: SIS 2142/SKF 280

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5. Physical and Connection Data

Instead of the welding nipples for R-KB pipes, it is possible to order welding nipples solely used for standard pipes in accordance with ANSI B31.5, schedules 80 and 40. Fig. 5.2 Welding Nipples for ANSI Pipes 305

The welding nipples are shown in Fig. 5.2 and must be specified when ordering a compressor.

1 OD1 OD OD2

ID1

ID2 ID1

ID2

S A
Table 5.5
Standard welding end for ANSI B31.5 pipes schedule 80 + 40 INCH. 2" 2 1/2" 2 1/2" 3" 4" 5" DN 50 65 65 80 100 125 OD 60.3 76.1 76.1 88.9 114.3 139.7 s 3.9 6.7 6.7 5.5 6.0 5.8 OD1 76.0 113.5 113.5 144.0 OD2 90.5 90.5 129.5 129.5 129.5 154.5 ID1 52.5 62.7 62.7 77.9 102.2 128.1 ID2 57.0 57.0 93.0 93.0 93.0 125.0 A 51.0 51.0 61.0 61.0 56.0 73.0 Mat. 2 2 1 2 2 2

Material: 1: RST 37-2 DIN 17100 2: SIS 2142/SKF 280

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5. Physical and Connection Data

Connections on SMC / TSMC Mk4


Fig. 5.3 Standard connections for both SMC / TSMC 10X and 11X AC Q 1 4 AF H

E C V D 05 physical and connection data.fm Fig. 5.4 SMC 112-116 Mk4 1 4 H AE AH AK AJ B A

P L O N T G U

Z AF

AD Y AA

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5. Physical and Connection Data

Fig. 5.5 AC

TSMC 108 Mk4 1 2 H 4 R 3 AF M

Fig. 5.6 1

TSMC 116 Mk4

AF 2

H, AL 4 R Y M AG AD Y 3

AK

Fig. 5.7

Top cover

Fig. 5.8 X, AN

Top cover w. flange

S Z, AL

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5. Physical and Connection Data

Fig. 5.9

Pump end

BD BX

BL BB

05 physical and connection data.fm

BE

BT

BP

BN

BJ

BS

BA

BQ

Fig. 5.10

Shaft seal end

F K AB AM

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5. Physical and Connection Data

Connections for T/SMC104-116


Numbers at position are referring to 1) SMC10X 2) SMC11X 3) TSMC108 4) TSMC116

Table 5.6
AIR-COOLED WITH BUILT-IN OIL COOLER TERMOPUMP WITH BUILT-IN OIL COOLER AIR-COOLED wATER-COOLED POS (COMP. TYPE) NORMAL APPLICATION THREAD (ISO228/1-G) PRESSURE OIL, GAS OR LIQUID FIG. NO. Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.10 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6 Fig. 5.3 Fig. 5.10 Fig. 5.3 Fig. 5.5 and Fig. 5.6 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.5 and Fig. 5.6 Fig. 5.7 Fig. 5.3 Fig. 5.3 Fig. 5.3 Fig. 5.8 Fig. 5.5 and Fig. 5.6 Fig. 5.8 Fig. 5.4 Fig. 5.8 Fig. 5.8 Fig. 5.4 and Fig. 5.6 Fig. 5.10

A B C D E F G (1) G (3) G (2+4) H


1)

1 1/4 3/4 1/2 1/2 1/4 1/4 1/2 1/2 1/2 1/4 1/4 1/4 1/4 1/4 1/4 1/2 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/2 1/2 3/4 1/2 3/4 1/2 1/2 1 1/4 3/8

Suction Suction Suction Suction Suction Oil Suction Suction Suction Discharge Suction Oil Suction Intermediate Suction Suction Suction Discharge Discharge Suction Discharge Suction Discharge Suction Discharge Suction Intermediate Discharge Discharge Discharge Suction Suction

Oil Oil Oil Oil Gas Oil Gas Gas Gas Gas Gas Oil Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas

+ + + Plugged Plugged + Plugged Plugged plugged + + + + + + Plugged Plugged Plugged Plugged + Plugged

+ + + + Plugged + + + Plugged + + + + + + Plugged + Plugged Plugged + Plugged

+ + + Plugged Plugged + + Plugged Plugged + + + + + + Plugged Plugged + Plugged + + + + + + Plugged Plugged + + + + Plugged

Heating rod Oil charging valve Oil temperature Oil temperature Available Oil pressure to unloading cylinder Return from built-in oil cooler Return from built-in oil cooler Available High pressure connection Oil return from solenoid valves Oil pressure to solenoid valves Low pressure connection Intermediate pressure connection Oil return from oil separator Available Return from built-in oil cooler Return from oil cooler (thermopump) Available Suction pressure to unloading cylinder Refrigerant cooled top cover Equalization to suction end of thermo pump Liquid supply to top covers Connection to built-in oil cooler Discharge gas temperature Plug for fixing intermediate bearing Available Purge valve (discharge pressure) Purge valve (discharge pressure) Purge valve (discharge pressure) Heating rod Available

J K L M1) (3+4) N O P (1+2+3) Q (1+2+4) Q (3) R (3+4) S T U V X Y (2+4) AN (3) Z (2) Z (4) Z (1+3) AA (2+4) AB

Not included Not included

Liquid Not included Not included Oil Gas Gas Gas Gas Gas Gas Oil Oil Plugged + Plugged Plugged + + + + Plugged + + Plugged Plugged + + + + Plugged

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5. Physical and Connection Data

AIR-COOLED WITH BUILT-IN OIL COOLER

TERMOPUMP WITH BUILT-IN OIL COOLER

AIR-COOLED wATER-COOLED

POS (COMP. TYPE)

NORMAL APPLICATION

THREAD (ISO228/1-G)

PRESSURE

OIL, GAS OR LIQUID

AC AD (2+4) AE (2) AF (1+2) AF (3+4) AG (4) AH (2) AJ (2) AK (2+4) AL (3)

1/2 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2 1/4 3/8 1/4 1/4 1/2 1/8 1/4 1/4 1/8 1/4 1/8 1/4 1/4

Suction Suction Suction Discharge Discharge Intermediate Suction Suction Suction Intermediate Intermediate Suction Oil Oil Oil Suction Oil Suction See application See application Oil Oil Oil See application

Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil

Used in connection with UNISAB + Plugged Plugged Plugged Plugged + + Plugged + Plugged + + + + + + + + + + Plugged Plugged + Plugged Plugged Plugged Plugged + + Plugged Plugged +

Suction temperature (superheat) Return from solenoid valve Return from built-in oil cooler Return from built-in oil cooler Return from built-in oil cooler Equalization from thermopump for intermediate pressure Equalization to suction end of thermo pump Liquid supply to top covers Return from built-in oil cooler Purge valve (intermediate pressure) Purge valve (intermediate pressure) Available Not recommended for use Prelubrication of compressor bearings Not recommended for use Not recommended for use Not recommended for use Not recommended for use Oil pressure after oil filter Oil pressure before oil filter Not recommended for use Not recommended for use Oil pressure Oil pressure before oil filter

Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6 Fig. 5.4 and Fig. 5.6 Fig. 5.4 Fig. 5.3 and Fig. 5.4 Fig. 5.5 and Fig. 5.6 Fig. 5.6 Fig. 5.4 Fig. 5.4 Fig. 5.4 and Fig. 5.6 Fig. 5.8 Fig. 5.6 Fig. 5.10 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.9 Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6 Fig. 5.5 and Fig. 5.6 Fig. 5.5 and Fig. 5.6 Fig. 5.3, Fig. 5.4, Fig. 5.5 and Fig. 5.6

Not included Not included Not included Not included Plugged + + Plugged Plugged + Plugged Plugged Plugged Plugged + + Plugged Plugged + + + + Plugged Plugged + Plugged Plugged Plugged Plugged + + Plugged Plugged +

05 physical and connection data.fm

AL (4) AM BA BB BD BE BJ BL BN BP BQ BX BS BT 1 2 (3+4) 3 (3+4) 4

Used in connection with UNISAB Q

Low pressure suction stop valve Low pressure discharge stop valve Connection from intermediate pressure High pressure discharge stop valve

1) Positioning

on the different block types may vary

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5. Physical and Connection Data

Electrical Connections
Fig. 5.11
Electromechanical Control

TT7 PT2

Computer Control, UNISAB II

TT5 7 PT1

6 1+2 3 4 5 6 7 8 9

PT3

TT6

8 PT1 PT2 PT3 TT5 TT6 TT7

9 Suction pressure Discharge pressure Oil pressure Discharge gas temperature Oil temperature Suction gas temperature

High and low pressure cut-out KP15 High pressure cut-out (intermediate pressure) KP5 Differential oil pressure cut-out MP55 Discharge gas thermostat KP98 Oil thermostat KP98 Computer control, UNISAB II Heating element Oil filter differential pressure

UNISAB II:
Supply voltage: 115 VAC 230 VAC 24 VAC Permissible variation: +10%/-15% Frequency: 45-65 Hz Power: 50 VA

MOTOR
Connection data for supply voltage: Permissible variation: Frequency: Power: VAC +10%/-15% 45-65 Hz kW

Where UNISAB II is supplied with 24 VAC, the connecting terminals supplying the heating elements must be supplied with 115 or 230 VAC, see Installation Manual for UNISAB II.

Supply voltage and motor power appear from the order sheet.

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5. Physical and Connection Data

Control of the Unit


The compressors are available with a. b. analogue reading and safety system, electromechanical control. UNISAB II reading, safety and capacity regulating system. Wiring connection appears from the wiring diagram included in each delivery. The system requires an external control board for the control of the capacity regulation. Control and safety automatics is described in detail in Section 4, Technical Description - Instrumentation. Re b: UNISAB II is described in detail in a separate Instruction Manual. This manual also includes a description of UNISAB II's general controls. Key diagrams and installation descriptions are included in a separate Commissioning Manual for UNISAB II. With a Control System not Delivered by YORK Refrigeration This section describes the instrumentation of the compressor/unit - see data for electrical components in Section 21, Appendices. The fundamental requirements which must be complied with in order to operate the unit are also described. If other control systems than the ones prescribed by YORK Refrigeration are used, YORK Refrigeration disclaim the responsibility for the correct control of the unit. Moreover, YORK Refrigeration will not be liable to pay damages for personal injuries or for damage to the unit or the refrigeration plant if caused by malfunctioning of the control system. On delivery the compressor is fitted with instruments, but not with any other electrical installations. Note: If UNISAB II is installed as the control system of the unit, the components mentioned below will be standard components. Moreover, the wiring will have been carried out from factory.

Re a:

1. Pressure Transmitters marked PT1, PT2 and PT3


As standard, the product is delivered with pressure transmitters of the type: AKS32 and AKS2050 from Danfoss - see data sheet in Section 21, Appendices. Connection data: Connect a three-wire cable to the terminals of the plug fitted at the end of the pressure transmitters. Supply voltage: 5 VDC Output signal: 4-20 mA Pressure transmitters are used for measuring: 1.1 Suction Pressure, PT1 The measurement is used to protect against too low suction pressure. Low suction pressure must stop the compressor. The control system can be adjusted in such a way that the compressor starts automatically at too high suction pressure. The set values must be within the permissible working range for compressors as stated in Section 6, Technical Data. 1.2 Discharge Pressure, PT2 The measurement is used to protect the compressor against too high discharge pressure. Too high discharge pressure must stop the compressor without automatic restart. The set values must be within the per-

05 physical and connection data.fm

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5. Physical and Connection Data

missible working range for compressors as stated in Section 6, Technical Data. 1.3 Oil Pressure across Mechanical Oil Pump Is calculated as oil pressure after oil pump PT3 minus suction pressure PT1. Too low oil pressure (< 0.5 bar) must stop the compressor without automatic restart. However, this alarm must be delayed 45 sec when starting the compressor. 2. Temperature Sensors marked TT5, TT6 and TT7 As standard, the unit is delivered with Pt100 temperature sensors of the type P2208. See data sheet in Section 21, Appendices. Connection data: The sensor is fitted with a plug of the type IEC 947-5-2 with four conductors. The connection is carried out by means of a PG9-screw-joint. The sensors are used for measuring:

2.1 Suction Gas Temperature, TT7 measuring range: -50C to +180C [-60F to +356F] 2.2 Discharge Gas Temperature, TT5 measuring range: -50C to +180C [-60F to +356F]. The measurement is used to protect the compressor against a too high temperature in the discharge gas pipe. Too high a temperature in the discharge gas pipe must stop the compressor without automatic restart. The set values must be within the permissible working range for the compressor as stated in Section 6, Technical Data. 2.3 Oil Temperature, TT6 measuring range: -50C to +180C [-60F to +356F]. The measurement is used to protect the compressor against too high an oil temperature. Too high an oil temperature must stop the compressor without automatic restart.

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5. Physical and Connection Data

Heating Element for Oil Heating


Fig. 5.12 Dimension Sketch for Heating Element
NV 50 G 1 1/4 Marking: Prod. no. Watt Volt Manu. date

50

30

L1 80 L2

Table 5.7

Table of Power and Application


Heating rods Used for L2 mm CMO - TCMO - SMC 100 - TSMC 100 158 175 HPO - HPC, SMC 180 - TSMC 180 VMY 347 /447 - 536 SAB 110 - 128 - 163 - 202 - 330

05 physical and connection data.fm

Power Watt 270 270 270 460 460 460

Voltage V 250 230 115* 250 230 115*

L1 mm

* Can be delivered with UL approval. All heating rods are executed in Degree of Protection IP54

Coils for Solenoid Valves1) 220/230 Volt 50/60 Hz 10 Watt 115 Volt 240 Volt 50/60 Hz 10 Watt 50 Hz 10 Watt

The coils form part of solenoid valve for capacity regulation, oil cooler and thermopump.

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6. Technical Data

6. Technical Data
The purpose of this document is to provide the technical data of the equipment. In this document technical data is defined as: 06 technical data.fm Data for compressor Data for unit Working range Handling the compressor Area of application Laying the foundation Noise level data Vibration data Test pressure for compressors Assessing the oil Selecting lubricating oil This document is primarily intended for designers, service engineers, sales personnel and prospective customers. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

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6. Technical Data

Technical Data for the SMC 100 Series


Table 6.1
Compressor type Number of cylinders Bore mm 1) SMC 104S SMC 106S SMC108S SMC112S SMC 116S SMC104L Single stage SMC106L SMC108L SMC112L SMC116L SMC104E SMC106E SMC108E SMC112E SMC116E TSMC108S TSMC116S Two stage TSMC108L TSMC116L TSMC116L TSMC116E
1) 2)

Stroke

Max/min speed nominal rpm 2)

Swept volume at max speed m3/h 271 407

Weight of compressor block kg 580 675 740 1250 1350 580 675 740 1250 1350 600 700 770 1300 1400 775 1400 775 1400 800 1450

Weight of compressor block lb 1279 1488 1631 2756 2976 1279 1488 1631 2756 2976 1323 1543 1698 2866 3086 1709 3086 1709 3086 1764 3197

4 6 8 12 16 4 6 8 12 16 4 6 8 12 16 6 LP + 2 HP 12 LP + 4 HP 6 LP + 2 HP 12 LP + 4 HP 6 LP + 2 HP 12 LP + 4 HP 120 100 80 120 100 1500/700 100 80 1800/700

542 815 1086 283 424 565 848 1131 339 509 679 1018 1357 339 679 424 848 509 1018

LP = Low pressure cylinder HP = High pressure cylinder Permitted max. speed varies with operation conditions- and refrigerant. See the Operating Limit Diagrams

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6. Technical Data

Table 6.2

Weight of Compressor Units


Direct driven Kg lb 1830 2039 2183 3660 3086 2337 3086 4189 5181 Belt driven Kg 880 970 1030 1820 1920 1130 1410 2080 2530 lb 1940 2138 2271 4012 4233 2491 3109 4586 5578 Excl. intermediate cooler Incl. intermediate cooler Excl. intermediate cooler Incl. intermediate cooler Remarks

Compressor Type

SMC 104 SMC 106 SMC 108 SMC 112 SMC 116 TSMC 108 TSMC 108 TSMC 116 TSMC 116

830 925 990 1660 1400 1060 1400 1900 2350

The weight is exclusive of electric motor

06 technical data.fm

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6. Technical Data

Weight of Electric Motors


Sizes SHORCH IP 23 kg IEC 160L IEC 180M IEC 180L IEC 200M IEC 200L IEC 225S IEC 225M IEC 250S IEC 250M IEC 280S IEC 280M IEC 315S IEC 315M IEC 315L IEC 355S IEC 355M IEC 355L IEC 355L 1790 2095 3946 4619 355 455 480 625 680 875 945 1050 783 1003 1058 1378 1499 1929 2083 2315 445 570 630 900 940 1200 1500 1600 1750 981 1257 1389 1984 2072 2646 3307 3527 3858 855 1885 1510 1550 3329 3417 730 830 1609 1830 190 210 240 265 419 462 529 584 235 309 340 518 681 750 240 335 360 460 515 529 739 794 1014 1135 340 445 490 720 785 750 981 1080 1587 1731 395 475 565 850 1000 1050 871 1047 1246 1874 2205 2315 lb kg 102 173 188 IP 54 lb 225 381 414 kg 80 98 128 165 190 PLS lb 176 216 282 364 419 170 205 235 375 452 518 260 290 388 573 639 855 kg 78 100 110 MOTOR TYPE LEROY SOMER LS lb 172 220 243 kg 120 135 184 FLS lb 265 298 406

(LA)1900 (LB)2150

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6. Technical Data

Compressor Capacity
Compressor capacity is calculated by means of the COMP 1 program in the YORK Match Master suite of programs.

Alternatively, contact your local dealer who can help dimensioning the compressor.

06 technical data.fm

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6. Technical Data

Dimension Sketches of Compressor Block


As standard execution the compressor block can be delivered with either an analog display and safety system, i.e. with pressure gauges, pressure sentive and thermostats, or with a UNISAB II system with display and safety facilities as well as capacity regulation of the compressor. To illustrate the structure of the dimension sketches, three examples have been included, Fig. 6.1, Fig. 6.2 and Fig. 6.3. Moreover, reference is made to Dimension and Piping Diagram, which includes dimension sketches of all compressors and units. However, during the final planning the latest dimension sketches from YORK Refrigeration are required.

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06 technical data.fm Fig. 6.1

510

25

SMC /TSMC 100 Mk4 - Engineering Manual

650 1100

275

MIN 250

80 200

4 5
1500

G 200

MIN 400

205

32

710

2 8
900

1 6

4XM22 HOLES

SMC 100, V-belt Driven, Anolog System

FOR OPERATING STOP VALVES

FOR WITHDRAWING V-BELT GUARD

FOR WITHDRAWING CRANKSHAFT

COOLING SYSTEM

CONNEC.FOR

LIQUID REFRIG.
K

4 III

R22 OIL COOLER

G1/4

R717 OIL COOLER (BOOSTER)

G1/4

R717 THERMOPUMP.SYSTEM
H MAX

G1/4 I II

WATER INLET AND OUTLET G3/8

(COMPR. WITH WATER COOLING ONLY)

WELDING CONNECTIONS

COMPR.

R717

(H)CFC

SMC 104

M76.1x4.5

M88.9x3.2

SUCTION

SMC 106

SMC 108

M88.9x4.85

M114.3x3.6

DISCHARGE

ALL

M76.1x2.9

FOR UNITS WITH UNISAB MOTOR WEIGHT K DRWG. EXCL. NO. 171438 880 KG 970 KG 1030 KG 315 280 171438 171438 250 MOTOR 225 200 1015 1135 1235 1335 915 FOUND. OF UNIT IEC TYPE H MAX OVERALL LENGTH AND WIDTH VARIES ACCORDING TO MAKE OF MOTOR AND TYPE FOR EXACT LENGTH USE DIMENSION H IN TABEL 4833-001_0

ADD 80MM

COMPR

MOTOR

TYPE

TYPE

A MAX

IEC

MM

MM

MM

MM

MM

MM

MM

MM

MM

SMC104

200-315M

2050

1115

1095

1000

275

440

350

635

635

SMC106

200-315M

2010

1090

1130

1035

275

395

395

645

620

SMC108

200-315M

2020

1130

1125

1030

300

405

405

665

635

C (OVERALL HEIGHT)

0178-931 - ENG
A (OVERALL LENGTH) 1455 141 F

Rev. 27.10.03
SABROE

MIN 620

600

6. Technical Data

121/288

Fig. 6.2

510

25

SMC /TSMC 100 Mk4 - Engineering Manual

650 1100 200

275

MIN 250

80 200 G

4 5
1500

MIN 400

205

32

710

2 8
900

1 6

4XM22 HOLES

FOR OPERATING STOP VALVES

FOR WITHDRAWING V-BELT GUARD

SMC 100, V-belt Driven, UNISAB II System

FOR WITHDRAWING CRANKSHAFT

COOLING SYSTEM

CONNEC.FOR

R717 OIL COOLER (BOOSTER) III

G1/4

R717 THERMOPUMP.SYSTEM I II

G1/4

WELDING CONNECTIONS

COMPR.

R717

(H)CFC

SMC 104

M76.1x4.5

M88.9x3.2

SUCTION

SMC 106

SMC 108

M88.9x4.85

M114.3x3.6

DISCHARGE

ALL

M76.1x2.9

H MAX

WATER INLET AND OUTLET G3/8

(COMPR. WITH WATER COOLING ONLY)

R22 OIL COOLER

LIQUID REFRIG. G1/4

4
MOTOR WEIGHT FOUND. OF UNIT DRWG. EXCL. NO. 171438 880 KG 1030 KG 970 KG 315 1435 280 1335 171438 171438 250 1235 MOTOR 225 1115 200 1015 IEC TYPE H MAX OVERALL LENGTH AND WIDTH VARIES ACCORDING TO MAKE OF MOTOR AND TYPE FOR EXACT LENGTH USE DIMENSION H IN TABEL

COMPR

MOTOR

TYPE

TYPE

A MAX

IEC

MM

MM

MM

MM

MM

MM

MM

MM

MM

SMC104

200-315M

2050

1168

1095

1000

275

440

350

635

635

SMC106

200-315M

2010

1053

1130

1035

275

395

395

645

620

4833-011_0

0178-931 - ENG

SMC108

200-315M

2020

1193

1125

1030

300

405

405

665

635

C (OVERALL HEIGHT)

122/288
A (OVERALL LENGTH) 1455 141 F

MIN 620

600

6. Technical Data

Rev. 27.10.03

06 technical data.fm Fig. 6.3

C (OVERALL HEIGHT)

32

510

25

205

MIN 200

390

MIN 400

0178-931 - ENG
B (OVERALL WIDTH) 555 2 FILTER 141 3 FOR WITHDRAWING CRANKSHAFT COOLING SYSTEM LIQUID REFRIG. G1/4 G1/4 G3/8 4 R717 OIL COOLER (BOOSTER) R717 THERMOPUMP.SYSTEM WATER INLET AND OUTLET 5 6 R22 OIL COOLER CONNEC.FOR FOR WITHDRAWING PISTONS AND SUCTION 1 FOR OPERATING STOP VALVES

Rev. 27.10.03
WELDING CONNECTIONS COMPR. SMC 104 7 SUCTION SMC 106 SMC 108 8 DISCHARGE ALL M88.9x3.2 M114.3x3.6 M76.1x2.9 R717 M76.1x2.9 (H)CFC M88.9x3.2 80 500 560 D M 4xM22 HOLES OVERALL LENGTH AND WIDTH VARIES ACCORDING TO MAKE COMPR TYPE IEC 160-180 SMC 104 200 225-250 250M 280 II M MOTOR TYPE MM IEC III 160 180 209 197 181 162 140 114 315 108 200 225 I 280 250 222 106 160-180 200 SMC 225-250 250M 280 315 180 200 SMC 225-250 250M 280 315 S S S TYPE MAX MM 1900 2100 2150 2250 1950 2150 2200 2300 2400 2000 2200 2250 2350 2450 1005 1125 440 270 185 875 443 1030 900 665 204847 171426 990 KG 995 1130 440 171427 270 160 875 418 1035 875 645 204847 171426 171427 925 KG 440 270 995 1095 135 900 393 1000 830 635 171427 204847 171426 830 KG MM MM MM MM MM MM MM MM MM MOTOR A OF MOTOR AND TYPE FOR EXACT LENGTH USE DIMENSION M IN TABEL BELOW B C D E F G H K L

MIN 620

A APPROX

6. Technical Data

SMC /TSMC 100 Mk4 - Engineering Manual

250

1250

6
WEIGHT FOUND. OF UNIT DRWG. EXCL. NO. MOTOR

SMC 100, Direct Driven, UNISAB II System

4843-021_0

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6. Technical Data

Planning the Machine Room


When planning the machine room, make sure that there is enough space around the compressor. The minimum spacing is indicated below, see Fig. 6.4, Fig. 6.5 and Fig. 6.6. Space 1: Space 2: Space 3: SMC 104-106-108, TSMC 108 600 mm [24] SMC 112-116, TSMC 116 Fig. 6.4 1100 mm [43] 500 mm [20] 400 mm [16]

1
Fig. 6.5 Compressor Block with Analog System Fig. 6.6 Compressor Block with UNISAB II System

Enough room must be left around the compressor to allow the operating personnel to operate the compressor and carry out service work on the compressor . Space should be considered as

sufficient space to make it possible to take out the crankshaft without dismounting the compressor from the base frame.

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6. Technical Data

Operating Limits Diagrams


To make sure that YORK Refrigerations customers experience a satisfactory compressor operation within the specified operating periods between the service intervals, it is essential that the operating conditions are kept within certain permitted operating limits. The operating limits are specified in the following Operating Limits Diagrams. YORK Refrigeration is only liable in so far as the operating limits conditions of the compressor are kept within the limitation of the curvas. Similary, the recommendation concerning the number of revolutions and cooling of the compressor must be observed. The limitation curves have been determined on the basis of both constructional and operating conditions. 1. Max Permissible Condensing Pressure: The pressure limit corresponds to the test pressure which is applied to all compressors and as indicated under Test Pressure in this section.
TC 1

2.

Max Permissible Differential Pressure across the Pistons:


TC 2

Fig. 6.8

TE

3.

Permissible Compression Ratios : The compression ratio is calculated into the diagram with the following values: Max. value or for: - R717 - R134a - R22 - R207C - R404A - R507 8 (7 for SMC 100 E) 12 10 10 14 14

06 technical data.fm

Fig. 6.7

Fig. 6.9
TC

TE
TE

3a.

Limitation of the Compressor rpm: The limitation has been introduced in order to avoid excessive discharge gas and oil temperatures.

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6. Technical Data

Fig. 6.10
TC 3a

Fig. 6.12
TC

5
TE

TE

4.

The Lowest Permissible Suction Pressure: The limit has been fixed at approx 0.5 bar and 5.6 bar for R744 (CO2 triple point).
TC

6.

Fig. 6.11

Minimum Difference between Condensing and Evaporating Temperature: If there is less difference than specified, the compressor will not get sufficiently warm. Lubrication problems may occur when the refrigerant content in the oil is too high with a subsequent risk of oil foaming in the compressor. It should also be noted that some of the equipment in a refrigeration plant requires a certain pressure difference in order to function properly.
TC

TE

5. The Lowest Permissible Condensing Pressure: At condensing pressures lower than the ones specified, the dampening effect from the gas on the valve plates against the valve retaining plate is reduced. This increases the risk of valve breakdown. 7.

TE

The Highest Permissible Evaporating Pressure: In the crankcase there will always be an evaporating pressure. An increase in the evaporating pressure will increase the load on the thrust bearing at the crankshaft as well.

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6. Technical Data

Furthermore, the refrigerant content in the oil is going to increase, primarily refrigerants used with soluble oil, and this may cause lubrication problems. The HFC and HCFC refrigerants, which are relatively heavy, will raise the pressure drop through the discharge and suction valves and this will impede the proper functioning of the valves. Fig. 6.13
TC 7

7a.

The Highest Permissible Evaporating Pressure: The limitation curves represent the highest permissible suction pressure without reducing the number of revolutions.
TC 7a

Fig. 6.14

TE

06 technical data.fm

TE

The following Operating Limits diagrams include the refrigerants: R717, R134a, R22, R407C, R404a, R410A, R507 and R744. The cooling systems for compressors which are mentioned in the Operating Limits Diagrams below are described in detail in Section 4, Technical Description - Cooling Systems for Compressors.

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6. Technical Data

TC
F C

R717
140 122 60 50 40 30 20 10 0 -10 -20 -30 -60 -50 -40 -30 -20 -10 -76
T0111123_1 VIEW 2

Condensing temperature

104 86 68 50 32 14 -4 -22

4 3 2

Operating Limits One Stage Compressor Type CMO & SMC

BOOSTER OPERATION

0 32

10 50

20 68

30 86

40 104

C F

-58 -40 -22

-4

14

TE

Evaporating temperature

TYPE

AREA max. 1-2 3-4 1-2 3-4 1 2-3-4

rpm min. 900 700 450

COOLING Air cooled top- and side covers # or water-cooled Thermopump or water-cooled Air cooled top - and side covers # or water-cooled Thermopump or water cooled Water-cooled

NOTE

CMO20 SMC100S/L SMC180

1800 1500 750 1000*

1) 1)

* SMC 188: 840 - 920 RPM not allowed. # Included refrigerant cooled oil cooler. Thermopump: Top and side covers are cooled by injected refrigerant. Oil cooling is included in the system. Water-cooled: Top and side covers are water-cooled. Oil cooling is included in the system. Discharge temperature must not exceed 150C (302F) at full load and at part load. 1) Discharge temperature at part load has to be checked.

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6. Technical Data

TC
F C

140 122 104

60 50 40 30 20 10 0 -10 -20 -30 -60 -50 -40 -30 -20 -10 -76 -58 -40 -22 -4 14 0 32 10 50 20 68 30 40
C F

R717
2 1 Operating Limits One Stage Compressor Type SMC100E

Condensing temperature

86 68 50 32 14 -4 -22

OPERATION

06 technical data.fm

86 104

TE

T0111140_0 view 6

Evaporating temperature

TYPE

AREA max.

rpm min. 700

COOLING

NOTE

SMC100E

1 2

1500

Thermopump or water cooled

1)

Thermopump: Top and side covers are cooled by injection refrigerant. Oil cooling is included in the system. Water-cooled: Top and side covers are water-cooled. Oil cooling is included in the system. Discharge temperature must not exceed 150C (302F) at full load and at part load. 1) Discharge temperature at part load has to be checked.

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6. Technical Data

TC
F C

158 140 122 104

70 60 50 40 30 20 10 0 -10 -20 -30 -40 -70 -94

R717
1 2 Operating limits Two Stage Compressors TCMO TSMC 100 S-L-E TSMC 180

Condensing temperature
0177128_0 VIEW 3,1

86 68 50 32 14 -4 -22 -40

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 C 104 F

TE

Type TCMO TSMC 100 S-L-E TSMC 180

Area 1-2 1-2 1 2

Evaporating temperature rpm Cooling max min top and side 1800 900 Thermopump or water-cooled 1500 750 1000 700 450 Thermopump or water-cooled Water-cooled

Note

1) 1)

Oil cooling is always necessary. Thermopump: Only the HP Stage top covers are cooled by a thermo pump. Oil cooling included in the system Water-cooled: Top and side covers. Oil cooling included in the system. Part-load operation: 1) Depending on the operating conditions and the pressure on the compressor, a by-pass system may be required. See section: By-pass system for two-stage compressors.

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6. Technical Data

TC
F C

R22
3 1 2 4 Operating Limits One Stage CMO & SMC

158 140 122 104 86 68 50 32 14 -4

70 60 50 40 30 20 10 0 -10 -20 -30 -60 -50 -40 -30 -20 -10


-76 -58 -40 -22 -4 14

06 technical data.fm

Condensing temperature

-22

0
32

10
50

20
68

30
86

40

104 F

TE

T0111-127_0 view 2

Evaporating temperature

TYPE

AREA MAX. 1 2 3 4 1 2 3 4 1 2 3 4 1-2 1500

RPM MIN.

OIL COOLING REQUIRED1) No 900 No At less than 50% capacity Yes No 700 No At less than 50% capacity Yes

REMARKS

CMO20

1800 1000 1200 1800

SMC100S

2) 1000 1200 700 No At less than 50% capacity yes Yes 2) 750 450 At less than 50% capacity yes Yes

SMC100L

SMC180

3 4

Top covers: Air-cooled only 1) When required, choose freely between A or B - except SMC180 where only A may be selected. A: Water-cooled side covers B: Built in refrigerant cooled oil cooler with thermostatic expansion valve. 2) Discharge temperature at part load has to be checked.

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6. Technical Data

TC
F C

R22
2 3 1 Operating Limits Two Stage Compressor type TCMO & TSMC

140 60

Condensing temperature

122 50 104 40 86 68 50 32 30 20 10 0 -60 -76 -50 -58 -40 -40 -30 -22 -20 -4 -10 14 0 C 32F

TE

T0111139_0 view 1

Evaporating temperature

TYPE

AREA 1-2 3 1 2 3 1 2 3 1-2 3

TCMO

TSMC100S

RPM MAX. MIN. 1500 900 1800 1000 1200 700 1800 1000 1200 750

OIL COOLING 1)

NOTE

No

Yes

2) 3)

TSMC100L

700

Yes

2) 3) 2)

TSMC180

450

Yes

Top covers: Air-cooled only. 1) When required, choose freely between A or B - except TSMC180 where only A may be selected. A: Water cooled side covers B: Built in refrigerant cooled oil cooler with thermostatic expansion valve. By-pass equipment required to maintain intermediate temperature at minimun load. (see price list specification). Not applicable.

2) 3)

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6. Technical Data

TC
F C

176 158 140 122 104

80 70 60 50 40

R134a
1 2

Operating Limits One Stage CMO & SMC

Condensing temperature

3
86 68 50 32 14 -4 -22 -40 30 20 10 0 -10 -20 -30 -40 -70 -94 40C 104F

06 technical data.fm

T0177128_ V8,1

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

TE

Evaporating temperature
TYPE AREA MAX. 1-2 CMO 3 1 SMC100S 2 3 1 SMC100L 2 3 1000 1200 No 700 No At less than 50% capacity 1200 1500 1800 1000 1200 1500 700 900 RPM MIN. No At less than 50% capacity No At less than 50% capacity No No No At less than 50% capacity 2) OIL-COOLING 1) NOTE

Top and side covers: Air-cooled 1) When required, choose freely between A or B A: Water-cooled side covers B: Built in refrigerant cooled oil cooler with thermostatic expansion valve. Not applicable.

2)

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6. Technical Data

TC
F C

158 140 122 104

70 60 50 40 30 20 10 0 -10 -20 -30 -40 -70 -94


C 40

R134a
1 2 3 Operating limits Two Stage Compressors TCMO TSMC 100 S-L

Condensing temperature

86 68 50 32 14 -4 -22 -40

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

T0177128_0 V8,1

104F

TE

Evaporating temperature

Type

Area 1-2 3 1 2 3 1 2 3 max 1500 1800 1000 1200 1500 1000 1200

rpm min 900

Oil-cooling required 1)

Note

TCMO 28

1)

TSMC 100 S TSMC 100 L

700

1)

2) Not applicable

700

1)

2)

1) 2)

Oil cooling: Not required. Top- and side covers: Only air-cooled. Part-load operation: By-pass equipment required to maintain intermediate temperature at minimum load.

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6. Technical Data

TC F 140 122 C 60 50 40 30 20 10 0 --10 1

R404A
Operating Limits CMO & SMC One Stage

Condensing temperature

104 86 68 50 32 14

--4 --20

06 technical data.fm

--22 --30 --60 --50 --40 --30 --20 --10 --76


T0111164_2

0 32

10 50

20 68

30 C 86 F

TE

--58 --40 --22

--4

--14

Evaporating temperature

TYPE

AREA MAX. 1500 1800 1200 1500 1200

RPM MIN. 900 700 700

OIL COOLING 1) No At less than 50% capacity No At less than 50% capacity No

NOTE

CMO20 SMC100S SMC100L

1 1 1

Top covers: Air-cooled design only. 1) When required, choose freely between A or B A: Water-cooled side covers. B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

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6. Technical Data

TC
F C

140

60

R404A
1 2 Operating Limits Two Stage TCMO & TSMC

122

50

Condensing temperature

104

40

86

30

68

20

50

10

32

14

-10 -70 -94

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 C 32 F

274263.3 Rev. 0

TE

Evaporating temperature

TYPE

AREA MAX. 1 2 1 2 1 2

RPM MIN. 900 700 700

OIL COOLING

NOTE

TCMO 28

1800 1200 1500 1000 1200

No No No 1) 1)

TSMC100S TSMC 100L

Top and side covers: Air-cooled only. 1) Part-load operation: By-pass equipment required to maintain intermediate temperature at minimum load.

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6. Technical Data

TC F 140 122 C 60 50 40 30 20 10 0 --10 --20 --30 --60 --50 --40 --30 --20 --10 --76
T0111166_2

R507
Operating Limits One Stage CMO & SMC
1

Condensing temperature

104 86 68 50 32 14 --4

06 technical data.fm

--22

0 32

10 50

20 68

30 86

C F

TE

--58

--40 --22

--4

--14

Evaporating temperature

TYPE

AREA MAX. 1500 1800 1200 1500 1200

RPM MIN. 900 700 700

OIL COOLING 1) No At less than 50% capacity No At less than 50% capacity No

NOTE

CMO20 SMC100S SMC100L

1 1 1

Top covers: Air-cooled only. 1) When required, choose freely between A or B A: Water-cooled side covers. B: Built-in refrigerant-cooled oil cooler with thermostatic expansion valve.

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6. Technical Data

TC
F C

R507
Operating Limits Two Stage Compressor TCMO & TSMC 1

140

60

122

50

Condensing temperature

104

40

86

30

68

20

50

10

32

14
274263.4 Rev. 0

-10 -70 -94

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 C 32 F

TE

Evaporating temperature

TYPE

AREA MAX. 1 2 1 2 1 2

RPM MIN. 900 700 700

OIL COOLING

NOTE

TCMO28 TSMC100S TSMC100L

1800 1200 1500 1000 1200

No No No 1) 1)

Top- and side covers: Air-cooled only. 1) Part-load operation: By-pass equipment required to maintain intermediate temperature at minimum load.

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6. Technical Data

TC C F

60

140 122 50 40 30 20 10 0 -10 -20 -30 -70 -94


T245411_0 view 2

R407C
1 Operating Limits One Stage Compressor type CMO & SMC

Condensing temperature

104 86 68 50 32 14 -4

06 technical data.fm

-22

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 C
TE

86 F

Evaporating temperature Type Area 1 2 3 1 2 3 1 2 3 1 2 3 rpm max 1500 1800 1200 1500 1200 1000 1200 1000 Oil-cooling required 1) no At less than 50% capacity yes no At less than 50% capacity yes no At less than 50% capacity yes Note

min 900

CMO

SMC 100 S

700

SMC 100 L SMC 100 L SMC

700

SMC 180

750

NOT APPLICABLE At less than 50% capacity 450 yes

Top covers: Air-cooled design only. 1) When oil cooling is required, choose freely between A or B however, for SMC 180, only A may be selected.

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6. Technical Data

Direction of Rotation of the Compressor


The normal direction of rotation for the compressors is anti-clockwise when looking at the compressor from the shaft end. Fig. 6.15 Direction of rotation for compressor seen from A pressor is connected to a combustion motor with a specified direction of rotation. In such cases the oil pump must be changed as it is uni-directional. The direction of rotation for the pump is indicated by a guide pin. Counterclockwise compressor rotation: Marking in cover to the right of the logo.

Fig. 6.17 Guide pin An arrow cast into the bearing cover indicates the direction of rotation as shown in the picture. Fig. 6.16

Clockwise compressor rotation: Marking in cover to the left of the logo.

Fig. 6.18

At times it may be necessary that the crankshaft rotates in the opposite direction, e.g. if the com-

Guide pin

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6. Technical Data

Choice of Electric Motor


The IEC electric motors type IP23 or IP54 (55) (IP= Index of Protection) are normally used to drive the compressors, and the base frames are standard design for these motors. Fig. 6.19 IP23 Drip-proof Motor

B.

Do consider, however, which type of plant the compressor is going to work on, and then dimension the motor in accordance with the following rules: a: For plants in which a higher ET may be expected, and consequently also a higher CT in the start-up phase, the motor must be dimensioned to meet the higher operating temperatures. Usually, this does not incorporate factor 1 and 2. Likewise, special consideration should be given concerning the booster compressors. b: Alternatively, the motor can be connected to a system for Ampere limitation which reduces the compressor capacity until the planned operating temperatures have been reached. This element is found in UNISAB II, which must be linked to the Amp. signal, however. In this case, factor 1 and 2 should also be omitted.

When selecting an electric motor, the following factors must be taken into consideration: 06 technical data.fm

Motor Dimension
The size of the motor is determined on the basis of the power demands of the compressor under the current operating conditions calculated by means of the YORK COMP1 PC program. However, for various reasons, always choose a motor a little bigger. The reason for this is explained in the following: A. Generally speaking, the calculated power demand should be increased by one of the following factors in order to ensure that the motor has sufficient driving power, both during start-up, at minor deviations from the worked out operating conditions and with regard to mechanical transmission loss for instance in the V-belt drive:
1: Air conditioning plant: 2: Other refrigeration plants: 3: For V-belt drive: Factor 1.10 Factor 1.15 Factor 1.05

Note: YORK Refrigeration would like to point out that when using a motor with a class F insulation (105K) for operating conditions like for class B (90K), approx. 10% continual overloading of the motor will be acceptable in connection with the nominal effect. As mentioned previously, all compressors are as standard completely unloaded during the start-up phase. This reduces the power consumption of the compressor considerably as may be seen from the starting torque curve, Fig. 6.20. As standard, the SMC 100 can only be capacity regulated in steps of two cylinders, which is usually satisfactory. If required, extended unloading can be ordered when the order is placed or it can be mounted at a later time. For more information on this subject, see Section 4, Technical Description - Extended unloading of the Compressor.

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6. Technical Data

The starting torque for compressors with extended unloading appears from and Fig. 6.22. Please note that moment of inertia is not included in the diagrams. Further pay attention to the fact that the motor should reach its maximum torque moment before the non-adjustable cylinders are put into operation. Fig. 6.20

The maximum time for reaching minimum rpm (TSMC 100 : 750 rpm.) is 5 sec. and nominal speed should be reached after max. 10 sec. For more information on this, see Section 4, Technical Description - Capacity Regulation and Unloading of the Compressor.

Starting torque at 0% load

500 116S 450


Start up torque for L-models: Diagram values x 1.6 Start up torque for E-models: Diagram values x 2.6

400 350
R717 (TE = +55C) HFC/HCFC (R507 TE = +55C)

112S

300
Torque (Nm)

250

108S

200 150

106S 116S 104S 112S 108S 106S 104S

100 50

250

500

750

RPM (/min)

1000

1250

1500

1750

2000

STARTING TORQUE FOR COMPRESSOR SMC/TSMC/HPC100

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6. Technical Data

Starting Torque of the Compressor


The motor size is usually selected as described in the previous section. With all cylinders unloaded during the starting-up phase the motor generally has sufficient starting power in order to bring the compressor at full speed before the cylinders are loaded. Read more in Section 4, Technical Description - Capacity Regulation and Start Unloading of the Compressor. At times, however, it may be a good idea to compare the starting torque curve of the compressor Fig. 6.21 Starting Torque Curve for Electromotors to the starting curve of the motor (this information can be obtained from the motor manufacturer). Especially, when the compressor starts at a plant pressure below normal and when power limiting systems are used to start up the motor, e.g. a Y/ starter, it may be necessary to work out a diagram as the one shown in Fig. 6.21. The hatched area represents the torque moment available to the motor when speeding up the compressor.

Kpm [Lb.ft.]

06 technical data.fm

Motor

starters

Motor Y starters

Compressor

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6. Technical Data

Start up torque SMC 100 R717 25% load

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6. Technical Data

Fig. 6.22

Start up SMC 100 - HFC/HCFC - 25% load

D p

06 technical data.fm

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6. Technical Data

Moment of Intertia
As to the moment of inertia, Table 6.3 and Table 6.4, the SMC/HPC/TSMC 100 compressors have the following values: Table 6.3
Type No of cylinders: SMC/TSMC 100 HPC 100 Compressor with free shaft end V-belt driven compressor with shaft pulley No of V-belts Profil SPB
4 4

Moment of Inertia (kgm2) for SMC/HPC/TSMC 100 Compressors


SMC 100 S (80 mm stroke)
6 8 12 16 4

SMC 100 L (100 mm stroke)


6 8 12 16 4

SMC 100 E (120 mm stroke)


6 8 12 16

4 0.154

6 0.189

8 0.218 0.376 0.427 0.196 0.234 0.269 0.464 0.579 0.254 0.321 0.340 0.593 0.705

1.529

1.564

1.593

1.751

1.802

1.571

1.609

1.644

1.839

1.954

1.629

1.696

1.715

1.968

2.080

6 8

1.404 1.779 0.262

1.439 1.814 0.297

1.468 1.843 0.326

1.626 2.001 0.559

1.677 2.052 0.610

1.446 1.821 0.304

1.484 1.859 0.342

1.519 1.894 0.377

1.714 2.089 0.647

1.829 2.204 0.762

1.504 1.879 0.362

1.571 1.946 0.429

1.590 1.965 0.448

1.843 2.218 0.776

1.955 2.330 0.888

Direct driven compressor with complete AMR coupling

Table 6.4
Type No of cylinders: SMC/TSMC 100 HPC 100

Moment of Inertia (Ib.ft2) for SMC/HPC/TSMC 100 Compressors


SMC 100 S (80 mm stroke)
4 6 8 12 16 4

SMC 100 L (100 mm stroke)


6 8 12 16 4

SMC 100 E (120 mm stroke)


6 8 12 16

4 3.66

6 4.49

8 5.18 8.93 10.14 4.66 5.56 6.39 11.02 13.75 6.03 7.62 8.08 14.09 16.75

Compressor with free shaft end V-belt driven compressor with shaft pulley No of V-belts Profil SPB
4

36.31

37.15

37.84

41.59

42.80

37.32

38.22

39.05

43.68

46.41

38.69

40.29

40.74

46.75

49.41

6 8

33.35 42.26 6.22

34.18 43.09 7.05

34.87 43.75 7.74

38.62 47.53 13.28

39.83 48.74 14.49

34.35 43.25 7.22

35.25 44.16 8.12

36.08 44.99 8.95

40.71 49.62 15.37

43.44 52.35 18.10

35.72 44.63 8.60

37.32 46.22 10.19

37.77 46.67 10.64

43.78 52.68 18.43

46.44 55.34 21.09

Direct driven compressor with complete AMR coupling

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6. Technical Data

Direction of Rotation of Electric Motor


Sometimes the motor is equipped with specially designed ventilation wings to reduce the noise level. These motors have a specified direction of rotation which must be considered when connecting them to a compressor. If the motor is connected by means of a coupling, it must rotate clockwise when looking at it from the shaft end, Fig. 6.23. Fig. 6.23 SMC 112-116 and TSMC 116 Clockwise, Fig. 6.25. Fig. 6.25 SMC 104-106-108 and TSMC 108 Anti-clockwise, Fig. 6.24. Fig. 6.24

06 technical data.fm

If the motor is connected by means of a V-belt pulley, the direction of rotation should be as follows:

Note: The driving part of the V-belts must always be closest to the base frame.

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6. Technical Data

Handling of Compressor and Unit


When lifting the compressor, only use the lifting eyes M20, Fig. 6.26, which are fitted in the threaded holes at the top of the block. The weight of the compressor block is indicated in Table 6.1 in the beginning of this section. Note: It is only the compressor block which may be lifted in the lifting eye. The same applies to the motor. Fig. 6.26

the wires do not get stuck and thus damage the pipes or any other components on the unit. Fig. 6.27

Alternatively, the unit can be lifted with a forklift truck. It is recommended to make the distance "x" as wide as possible yet still keeping it within the supports as illustrated in the Fig. 6.28. Be careful that the unit does not tip sideways as the point of gravity is rather high. Fig. 6.28

The unit is lifted in the lifting eyes, which are welded onto the base frame and clearly marked with red paint. When the unit is lifted, make sure that

The weight of the unit can be seen in the shipping documents or in Table 6.2.

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6. Technical Data

Compressor Shaft
All compressors have the same shaft size. On the shaft it is possible to mount either coupling flange or V-belt pulley as described in the following. The coupling flange or the V-belt pulley is fixed by means of a cone clamping system. Fig. 6.29 Coupling Types AMR 312 for: - SMC 104-106-108 and TSMC 108. - HPC 104-106-108. AMR 350 for: - SMC 112-116 and TSMC 116. Just like the flange to the compressor, the motor coupling flange has been duly balanced from factory. This makes special demands on the accuracy of the boring procedure. Boring Procedure The coupling flange is fixed in a lathe or a fine boring machine by tightening the outer diameter C of the flange, Fig. 6.30. 06 technical data.fm Fig. 6.30 Boring of Hub The coupling flange or the pulley is usually mounted on the compressor shaft on delivery of compressor units. On delivery of compressor blocks where the customer prefers to bore the hub himself, the following procedure should be observed: It is recommended to use the types of coupling as stated for SABROE compressors. If the necessary data is not known on delivery of the compressor, the coupling flange for the motor will be delivered pilot bored and the boring must be completed on site. AMR Coupling Flange to Motor Shaft
C A

Max. 0.02 mm

Alignment must be kept within the values stated in Table 6.5.

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6. Technical Data

Table 6.5
Max. axial untruth measured at point A Max. radial untruth measured at point B 0.02 mm 0.02 mm

Fig. 6.31
H7

Boring is carried out to the immediate motor shaft diameter with an H8 tolerance. Please, note that the max. boring diameter is 95 mm and that two key grooves must be engraved in the key of the motor shaft in order to maintain balance. The width of the key grooves is made with an H7 tolerance, and the depth must be such as to create a distance between key and hub of 0.2-0.3 mm, Fig. 6.31

+0.2/0.3 mm

H8

Max. dia. 95 mm

As seen in the above drawing, Fig. 6.30, the coupling hub is slit up axially and clamped to the motor shaft with two screws. Read more about the coupling in the following section.

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6. Technical Data

Coupling
An AMR coupling is used for YORK Refrigeration's Sabroe reciprocating compressors. This coupling is resistant to torsional stress but radially and axially flexible. Torsional resistance is achieved by a transmission of the rotational force of the motor through a number of thin laminated steel sheets (laminas) collected in two "parcels" (disc packs) A and fixed on the flanges with screws, Fig. 6.32. Fig. 6.32
A B A

provided that the motor comes from YORK Refrigeration. Intermediate piece and parcels with laminas are delivered separately and must be mounted on site. Remember that compressor and motor must be aligned as described in Section 7, Installation Instructions. Intermediate piece B also makes it possible to remove the shaft seal of the compressor without having to move motor or compressor. The length C of the intermediate piece (Fig. 6.33) and the lamina parcels cover a distance - after they have been dismantled - that makes it possible to dismount the coupling flange and the shaft seal of the compressor. Fig. 6.33

06 technical data.fm

With the torsionally resistant coupling the oscillatory weight of the rotor in the electric motor works as a "flywheel", providing the compressor with a stable and vibration free operation during all kinds of operating conditions and capacity stages. Radial flexibility is achieved by means of the intermediate piece B which, together with the two laminas "parcel A", creates a cardanic effect. In this way the two flanges are able to move a little radially in relation to each other, thus equalizing minor lateral movements of motor and compressor. The compressor unit is delivered with coupling flanges mounted on the compressor and motor, Table 6.6
Compressor HPC/SMC 104 - 106 - 108 TSMC 108 SMC 112 - 116 TSMC 116

Distance C mm 102 113

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6. Technical Data

The procedure for alignment of compressor and motor is described in Section 7, Installation Instructions. Balancing must be made before the key groove is engraved. Table 6.7
Compressor Coupling hub - motor Coupling hub - compressor HPC/SMC 104-106-108 TSMC 108 AMR 312 S AMR 312

After boring, the coupling flanges are balanced. This is characterized by one or more holes on the side of the flange. Max. permissible imbalance can be seen from the table, Table 6.7.

SMC 112-116 TSMC 116 AMR 350 S AMR 350

Balancing G mm 550 400

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6. Technical Data

V-Belt Drive for SMC/TSMC 100


Fig. 6.34

such narrow tolerances that they can be fitted immediately, which means that it is no longer necessary to check whether the belts match. A V-belt drive which has been set up and adjusted correctly will usually have a service life of approx. 20,000 operating hours. Fig. 6.36

06 technical data.fm

By letting the electro motor drive the compressor through a V-belt drive, the speed of the compressor can be selected so that the max. capacity corresponds to the capacity requirements of the plant. The V-belts are referred to as SPB Red Power. Their cross section dimensions are shown in Fig. 6.35 Fig. 6.35 S = C plus SPB 2650
16.3

Transmission Ratio
The required transmission of speed between motor and compressor is achieved by choosing the right combination of pulley diameters as stated in the Table 6.8. It appears from the table that there is only one pulley diameter for the compressors and that the transmission ratios are achieved by choosing among the standard motor pulleys. Thus the Compressor Speed for Motor Speed 1460 rpm (50Hz) and 1760 rpm (60 Hz) stated in the table is achieved. The nominal V-belt length is stated in the column Length of V-belt, and the same length is stamped on the outside of the V-belts as in the example shown in Fig. 6.36.

13

The V-belts are of an excellent quality. Under normal operating conditions they do not require any service and are shape-permanent, which means that they can be characterised as S = C plus, which is stamped on the outside of the belts, see Fig. 6.36. Moreover, the V-belts are made with

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6. Technical Data

Table 6.8

Standard Programme for V-Belts and Pulleys for SMC/TSMC 100


Compressor speed compared to Motor speed 50 Hz 1460 rpm 60 Hz 1760 rpm 792 836 *730 817 912 976 1022 1150 1273 1295 1460 880 985 1100 1166 1232 1386 1474 1562 1760 2650 2650 2650 2800 2800 2800 2800 3000 3000 3000 Length of V-belts mm SMC 104- 106-108 SMC 112- 116 TSMC 108 TSMC 116 1900 1900 1900 2000 2000 2000 2000 2120 2120 2240 2240

Standard V-belt pulley Diameter mm Compressor Motor 180 190 200 224 400 250 265 280 315 335 355 400

* SMC 104 - 108 and TSMC 108 only

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6. Technical Data

Power Transmission
The number of V-belts which must be used to transmit the necessary power from the motor to the compressor - which usually corresponds to the nominal capacity of the motor - is stated in the following tables, Table 6.9 and Table 6.10. Note: To obtain a smooth transmission, the number of V-belts must be chosen so that the belt drive loads at its maximum as stated in the table. The motor pulleys are always delivered with the number of grooves corresponding to the number

of V-belts which must be used to transmit the maximum power of the motor to the V-belt drive in question, thus indicating how many V-belts must be fitted. The compressor pulleys, however, are only delivered with the number of grooves shown below. Thus it may occur that there are more grooves on the compressor pulley than on the motor pulley. SMC/TSMC 100 The compressor pulleys are always delivered with 4 - 6 or 8 grooves.

Table 6.9
Number of V-belts

Max. Power Transmission SMC104-106-108 and TSMC108


Motor speed 1460 rpm (50 Hz) 730 817 22 37 45 55 75 90 75 106 912 30 45 55 976 30 45 55 75 90 110 1022 30 45 55 75 90 118 1150 37 55 75 90 110 132 1295 45 55 90 110 132 150 1460 45 75 90 110 132 169 kW rpm

06 technical data.fm

2 3 4 5 6 8 Number of V-belts

22 30 37 45 55 75

Motor speed 1760 rpm (60 Hz) 792 836 26 44 54 66 66 90 880 36 44 54 66 90 108 985 26 26 36 54 44 54 66 90 127 1100 36 44 66 1166 36 54 66 90 108 132 1232 36 54 66 90 108 143 1386 44 66 90 108 132 158 1474 44 66 90 108 132 171 kW rpm

2 3 4 5 6 8

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6. Technical Data

Table 6.10
Number of V-belts

Max. Power Transmission (kW) SMC112, 116 and TSMC116


Motor speed 1460 rpm (50 Hz) 730 817 912 55 55 75 90 106 110 976 55 75 1022 55 75 90 110 1150 55 75 90 110 132 1295 55 75 90 110 150 1460 55 90 110 132 169 kW rpm

3 4 5 6 8 Number of V-belts 792 3 4 5 6 8 54 66 66 54 54 66 90 108 54 66 90 108 66 836 880

Motor speed 1760 rpm (50 Hz) 985 1100 1166 66 90 132 1232 54 66 90 108 132 158 108 1386 66 1474 66 90 108 132 158 kW rpm

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6. Technical Data

Construction of V-Belt Drive


On standard units the nominal shaft distance between motor and compressor is 900 mm for SMC/TSMC 104 to 108 as shown in Fig. 6.37, and 500 mm on SMC/TSMC 112 and 116 as shown in Fig. 6.38. Fig. 6.37 SMC 104-106-108, TSMC 108
Nominal center distance 900 mm

Fig. 6.39

06 technical data.fm

Fig. 6.38

SMC 112-116, TSMC 112-116


II

The compressor pulley is bored with a cylindrical hole and is fitted to the crankshaft with a clamping unit. The end of the crankshaft and the outer face of the clamping unit must be aligned. Thus the belt pulley can be mounted on the crankshaft without previous adjustment. It must be tightened with the nine screws on the clamping unit, see fig. 6.41. The screws are tightened with a torque wrench. Fig. 6.40

III

Nominal center distance 500 mm

Align these faces

The driving part of the V-belts must always be closest to the base frame as shown with A in Fig. 6.39. Fig. 6.41

When dismounting the belt pulley, loosen the screws on the clamping unit.

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6. Technical Data

The motor pulley is tightened to the motor shaft by means of a conical bushing, pos. 1 in Fig. 6.42, which fits the conical boring of the belt pulley. The bushing is bored and equipped with a key, which fits the motor shaft in question. When mounting the pulley, first place the belt pulley and the bushing on the motor shaft, then fix the pulley to the bushing by means of two or three screws, pos. 2 in Fig. 6.42. Mount the screws in the holes where the thread faces the belt pulley. Thus the conical bushing is pressed around the motor shaft so that it both holds and centers the belt pulley. Before tightening, the belt pulley is placed on the motor shaft so that it is flush with the compressor belt pulley. Tighten the screws, pos. 2, with the torque moment as indicated in Section 21. Fig. 6.42

Tightening and Adjusting the V-Belt Drive When the necessary number of belts have been mounted - corresponding to the number of grooves on the motor pulley (max. 8) - the V-belt drive is tightened by moving the motor away from the compressor. For this purpose, use two washers which are part of the base frame and mounted at the feet of the motor. For measuring the correct belt tension, use Tension Gauge II, part no. 1622.003. Spare Parts When delivering belt pulleys as spare parts, the compressor pulley is always ready bored and balanced. It can thus be fitted directly on the compressor. The motor pulley is delivered balanced and with a conical bushing, which is ready bored for direct fitting on the motor shaft in question.

1 2

Service
The V-belt drive has an average service life of approx. 20,000 operating hours during which period it is only necessary to check and perhaps adjust the belt tension. Checking and adjusting the V-belt drive is best carried out by means of the special tool (Tension Gauge) mentioned above, which is available from YORK Refrigeration After-Market Service Department. When replacing the V-belts, the grooves in the V-belt pulleys should be checked for wear and tear by means of a Belt and pulley groove gauge, part no. 1622.001, which can also be obtained from our After-Market Service Department.

When dismounting the belt pulley, first dismount the two or three screws, pos. 2, and then mount one or two of the screws in the free hole/s where there is only a thread in the side which faces the bushing. By tightening the two screws evenly, it is now possible to press the belt pulley off the bushing. The bushing and the belt pulley can now be dismounted manually. The V-belts must only be mounted and dismounted when the motor is placed close to the compressor to avoid damage of the belts.

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Laying the Foundation


When erecting a compressor unit, it is important that the bed plate upon which it is placed is as plane as possible as the rigidity of the base frame depends on whether the base frame is supported correctly under all its "feet". The base frame should therefore be stress-free and rest evenly on all its "feet" when positioned on the foundation. In the following paragraphs a distinction is made between stationary plants and marine plants. Stationary Plant In stationary refrigeration plants the compressor unit is either mounted directly on a concrete foundation or positioned on vibration dampers, Fig. 6.43 and Fig. 6.44. 06 technical data.fm Fig. 6.43 Unit mounted directly on concrete foundation Fig. 6.44 Unit mounted on vibration dampers

The most preferred form of mounting today is the one on vibration dampers as the unit can be positioned directly on the machine floor without any clamping and without the laying of a concrete foundation. This reduces the plant costs considerably both during the initial installation and later on during a potential rearrangement of the units in the machine room. Further, the use of vibration dampers is a way to ensure that vibrations from the unit are not propagated to the construction itself via the foundation. In return, this form of mounting requires a plane and horizontal machine floor within narrow limits as specified in the following.

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Mounting Directly on Foundation: Mounting directly on the foundation or the floor of the machine room. The base plates of the unit are clamped down by means of foundation bolts, cast into the foundation as shown in the drawing. Fig. 6.45 Example of Foundation Drawing

Fig. 6.46

Moulding of Foundation Bolts

Foundation plate

300
250

10

Foundation bolts 125


110 x 110

Compressor

Motor

500 125
After the foundation has hardened, the unit is located, leaving it to rest on wooden blocks in a flush position and without twisting the base frame. The foundation plates are tightened under the base plates of the base frame by means of steel wire. The foundation bolts are suspended in the holes with the nut screwed down flush with the end of the foundation bolt as illustrated in the drawing. The concrete poured round the foundation bolts should only contain very little water in order that it may be stamped down properly round the bolts. A low water content does not cause contraction of the setting concrete. 10-14 days should be allowed to pass before the joists are removed and the nuts of the foundation bolts tightened. Remember to remove the steel wire and check that no space is left between base frame and foundation plates. Otherwise, place the liners between the plates before tightening.

300

1250

350

Foundation bolts, nuts and foundation plates are delivered together with an order. Following a specific order a foundation drawing will be forwarded and the holes poured into the foundation as indicated in this drawing. As shown in the drawing, Fig. 6.45, the unit is placed on a concrete foundation which is usually 300 mm high. During the concreting the holes are moulded into the concrete as indicated in the forwarded drawing, Fig. 6.46.

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Mounting of Vibration Dampers


By placing the compressor unit on vibration dampers, Fig. 6.44, calculated and delivered by YORK Refrigeration, an optimum damping of vibrations from the unit to the foundation and consequently to the construction will be achieved. As already mentioned, the unit with the vibration dampers is usually placed directly on the floor which must be strong enough to be able to carry the weight of the unit. The vibration dampers need not be clamped to the floor as the bottom side has a rubber coating, the friction of which prevents them from sliding around on the floor. This makes it easy and quick to align the units on a plane floor and they are easily moved during a potential later rearrangement of the machine room. Vibration Dampers: From the table in Fig. 6.48 it is possible to read how much the damping of a vibration damper depends on its deflection when loaded. YORK Refrigeration recommends that vibration dampers be selected and loaded to a deflection of nominally 2 mm. A good and rigid support of the unit is thereby achieved as well as a proper damping coefficient. The rotating parts in the compressor are completely balanced for forces of the 1st order and consequently, damping is primarily necessary for forces of the 2nd order, which rotates at double speed. In the table in Fig. 6.47 the normative values for damping can be read in relation to the number of revolutions: Fig. 6.47
rpm

Guide for Selection of Suitable Deflection


Suitable deflection order 2.3-3mm 1.6-2.4mm 1.2-2.0mm 0.8-1.4mm Damping of 1st order vibrations 25-50% 30-60% 40-72% 40-74% Damping of 2nd order vibrations 87-92% 87-92% 90-94% 89-94%

06 technical data.fm

950 1150 1450 1750

In the diagram in Fig. 6.48 the vibration damping with various vibration speeds can be read in dependence of the deflection of the vibration dampers:

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Fig. 6.48

Diagram for Damping of Vibrations

3000 Damping 98% 97%


Vibrationspeed rpm
Rev. 27.10.03

2500 95% 90% 85% 80% 70% 50% 0% Natural frequency 700 1000 1400 2000

500 30 20 16 12 10 8 6 5 4 3 2 1.6 1.2 1 0.8 0.6 m m

Deflection of vibration dampers

Since each part of the unit has its own weight, the whole unit does not rest with the same weight on all supports.

As a consequence, vibration dampers with different bearing capacity will be used on a unit and these must be placed correctly in accordance with the Mounting Instruction supplied by YORK Refrigeration for that particular unit. Fig. 6.49 is an example of such an instruction.

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Fig. 6.49

5
Vibration absorber type Pos. 1 A-B-C LM LM LM LM D LM LM LM LM LM LM

Compressor Unit A

Motor

Compressor Unit B

Motor

2 3 4 5

06 technical data.fm

Vibration dampers can be adjusted in height by means of screw, pos.1, Fig. 6.50 which is finally locked by tightening nut, pos. 2. The height H can now be changed within the limits stated in the table and are thus able to even out any minor differences in the planeness of the floor. Fig. 6.50
1 2
Baseframe

a loaded state, corresponding to the deflection referred to in the diagram in Fig. 6.48. When designing the piping connections to the compressor, care must be taken that these do not influence the push and pull forces of the unit. The length of the pipes changes with the temperature and this makes it necessary to make the pipings flexible as shown in the drawing, Fig. 6.51. Fig. 6.51

h H D 1 2

D LM1 LM3-4T025 LM3-33 80 120 120

h 30 37 32

H 38 49 44

Make sure, however, that the pipes are supported so that they do not start oscillating, thereby affecting the unit. After alignment of the unit as described above, compressor and motor must be aligned in relation to each other.

After this equalizing a further tightening of screws will lead to a deflection of the vibration damper. This reduces the measure h from an unloaded to

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Specific Requirements to Vibration Damping In places where particularly strict requirements are set up in order to prevent vibrations from being propagated to the building construction itself and causing noise nuisance, specific measures should be taken. This could be in connection with housing and office buildings or e.g. hospitals. In such cases the best results are achieved by fastening the whole unit on a sufficiently large concrete foundation which is placed on vibration dampers with a large bearing capacity or on a rubber mat adapted to the purpose. At the same time flexible vibration eliminators should be used in the pipe connection to the unit in order to avoid transmission of noise through the piping. Very often it will be necessary to insulate the machine room against noise or to use a noise absorbing lining on the unit, Fig. 6.52, in order to prevent noise from spreading to the environment. Fig. 6.52 Noise absorbing shielding of compressor unit

In case of questions, please contact YORK Refrigeration whose employees are always ready to place their expertise at your disposal.

Marine Installations
Units in marine refrigeration plants are always placed on vibration dampers as they serve a twofold purpose in so far as they dampen both the vibrations of the marine engines as well as those of the compressor. Fig. 6.53 Vibration dampers for marine installations

Liner plate

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The illustrated type of vibration dampers, Fig. 6.53, which is standard equipment on YORK Refrigeration's Sabroe reciprocating compressors, is fixed to the unit feet and foundation. This keeps the unit fixed to the foundation under all kinds of load conditions when the ship is exposed to the sea. It is not possible to adjust the height of the vibration dampers. This makes it necessary to machine the steel foundation as evenly as possible (max. deviation approx. 1 mm). Fig. 6.54

In case of a larger tolerance on the planeness or where vibration dampers of different heights are used due to the fact that the base frame loads differently on the surfaces of support, this must be compensated with liner plates as shown on the drawing, Fig. 6.53 Vibration dampers are selected by YORK Refrigeration for a particular unit and delivered together with a drawing indicating the position of each damper.

Vibration absorber type Pos. 1 2 Unit A C C C C Unit B C C C C C C

06 technical data.fm

3 4 5

It is very important to observe these positions as the unit does not rest with the same weight on all feet.

The vibration dampers are selected to a deflection of 3 to 5 mm. A damping of the forces of the 2nd order is thereby achieved as indicated in the diagram in Fig. 6.54. Read more on this subject in this section under Vibration Dampers.

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6. Technical Data

Noise from Compressors and Units


Noise is inevitable when a compressor or unit is working. However, by taking this into consideration during the project phase, it is possible to reduce noise pollution of the environment considerably. Through the years YORK Refrigeration has been aware of this problem. As a consequence, we have designed the compressors and units with a view to meeting market demands concerning maximum noise levels. Of course, modern compressor units are loud and must be expected to make noise, and this makes it the more important that the sound data stated for a compressor or unit should be evaluated correctly. The above issue will be discussed in the following. In this connection YORK Refrigeration would like to point out that at a fairly low cost it is possible to make the machine room a pleasant work place. The use of noise absorbing materials could be one solution to the problem. Fig. 6.55 Unit covered with a measuring grid

1.

Sound Power and Sound Pressure

As seen in Table 6.12 sound data is indicated as sound power level LW or sound pressure level LP. It is essential to distinguish between these two values as they are stated in dB (decibel) and should be read as follows: 1.1. Sound Power Level LW According to ISO 9614-2 LW is measured directly at the unit, Fig. 6.55, by installing a measuring grid as close to the unit as possible.

The measuring grid is divided into fields of max.1 sq. m each. The measuring is carried out by moving the sound level meter in a kind of back and forth movement, as illustrated in Fig. 6.55. The sound level meter now calculates the total sound power level LW for the entire unit. The sound power level LW is, however, dependent on the surroundings of the noise source. Consequently, it is a somewhat theoretical value. Here, the sound pressure level Lp becomes of interest.

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1.2. Sound Pressure Level Lp It is actually the sound pressure level Lp that is measured by the sound meter. In the sound meter this is then automatically converted to the sound power level LW by means of its built-in calculation programs. The sound pressure measuring is, however, dependent on the room in which the measuring is carried out. As a consequence, this may yield different results from one room to another. The arrangement of the room as well as building materials have a considerable influence on the results of the measuring. This is why the measured values of the manufacturers for sound pressures are based on standard measures according to ISO 3989 which refers sound pressure level LP to a free field above a reflecting plane at a distance of 1 meter from the measuring grid, as described in pt. 1.1. Above facts should be taken into consideration during a check measuring on the plant in question as mentioned in points 2.1 and 2.3.

1.3. Frequency Sound is fundamentally a pressure wave in the air at a given wave length (frequency). From a compressor unit sound waves are emitted at many different frequencies due to the different movable parts. The human ear can normally perceive frequencies in areas ranging from 20 Hz to 20 k Hz, but it does not perceive all frequencies equally well. Consequently, a sound meter must measure the sound pressure at various frequencies and then filter the measuring corresponding to the perceptual capacity of the ear (the A-weighting). To this must be added the purely subjective perception of sound as most human beings feel considerable unease on hearing the so-called "pure" notes. If a frequency is followed by a sound pressure of 3-6 dB above the other frequencies, this feels annoying. In case of screw compressors, it is a fact that 300 and 600 Hz is normally felt to be annoying whereas reciprocating machines issue a more low-frequency (pleasant) sound.

06 technical data.fm

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2.
2.1.

Assessing the Measured Values

Fig. 6.56

Curve for adding of logarithmic levels

As a consequence of the difference between the actually measured sound and the sound that the ear perceives, the measured values are weighted in the sound meter. Usually, the sound meter is set for A-weighted values called dB (A), based on a logarithmic scale. That is why it is so important to apply the same unit of measure on comparing values from several different machines. Further, we would like to point out that the sound pressure level LP measured in the machine room as described under pt. 1.2 will always be above the one indicated in table, Table 6.12 The measured value will normally lie somewhere between the stated LP and LW values. 2.2. In machine rooms with a number of compressors the total sound pressure level can be calculated by adding L read on the curve in Fig. 6.56 to the sound pressure value for the unit with the highest sound pressure.

3,0 2,5 2,0

L 1,5
dB 1,0 0,5 0 5,0

10,0

15,0

Difference (L2-L1) dB Example 1: With two compressors in the same room Compressor 1,LP1= 81 dB (A) Compressor 2,LP2= 86 dB (A) Difference 5 dB (A) Total sound pressure level: LP = 86 + 1.2 = 87.2 87 dB (A) Example 2: In case two compressors have the same sound pressure level, e.g. 86 dB (A) the difference will be 0. total sound pressure level: LP = 86 + 3 = 89 dB (A) Example 3: With a number of compressors in the same room the sound pressure level is calculated by miner of the curve, Fig. 6.57, as follows:

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Fig. 6.57 3 compressors

56 57,5

52

61

dB

62,6
6 compressors

63 dB

48 55,0

54

61

62

62

58

dB

62,0 65,0 66,7 67,2


2.3. 06 technical data.fm It is essential that during a potential check measuring to carry out more than one sound pressure measuring, e.g. by measuring in fields as shown in Fig. 6.55 as a few local measures may result in incorrectly high measured values. 2.4. Likewise, pay attention to the fact that the measured values stated for a certain unit should comprise a complete unit incl. compressor, motor, oil

~
=

67 dB

separator etc. which have all been covered by the measuring grid. Thus, on assessing the measure results it is essential to know the extent of the measured surface area in the surrounding measuring grid. 2.5. If the compressor is working at part load, this will generally lead to higher measured values than the ones indicated in the tables.

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3.
3.1.

How to Check Sound Data

Table 6.12
Compressor block SMC 104 S SMC 106 S SMC 108 S SMC 112 S SMC 116 S SMC 104 L SMC 106 L SMC 108 L SMC 112 L SMC 116 L SMC 104 E SMC 106 E SMC 108 E SMC 112 E SMC 116 E LW 95 96 97 99 100 96 97 98 100 101 96 97 98 100 101 Lp 79 80 81 82 83 80 81 82 83 84 80 81 82 83 84

The only correct method is the measuring of sound power LW on the site itself and this requires the setting up of a measuring grid as well as the use of sound intensive equipment. 3.2. If using sound pressure Lp meters only, an additional measuring of the reverberation period of the room will be required. This makes it possible to find a theoretical value of the emitted sound power provided that the background noise is too low to be of any importance!

Noise Data for Reciprocating Compressors


Single-stage LW and Lp values are measured at the following conditions: Evaporating temperature ET = 5C [5F] Condensing temperature CT = +35C [95F] Refrigerant = Number of revolutions = R22/R717 1450 rpm

Two-stage LW and Lp values are measured at the following conditions: Evaporating temperature ET= 35C [-31F] Condensing temperature CT= +35C [+95F] Refrigerant= Number of revolutions Table 6.13
Compressor block LW 95 97 96 98 96 98 LP 79 81 80 82 80 82

R22/R717 = 1450 rpm

Heat Pump Evaporating temperature ET = 20C Condensing temperature CT = +70C Refrigerant = Number of revolutions = R22/R717 1450 rpm

TSMC 108 S TSMC 116 S TSMC 108 L TSMC 116 L TSMC 108 E TSMC 116 E

Table 6.11
Compressor block HPO 24 HPO 26 HPO 28 HPC 104 S HPC 106 S HPC 108 S LW 91 93 94 97 98 99 LP 76 78 79 81 82 84

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4.

Damping Acoustic Noise in a Machine Room

On planning or renovating a machine room, attention should be paid to the acoustic environment as a minor investment is sufficient to change an acoustically hard room to a noise damped room which is pleasant to work in. This is possible to achieve by choosing a sensible noise absorbing material, fitted on walls and ceiling or which is part of the building construction It is recommended to seek advice from a consulting firm experienced in noise damping in order to obtain the solution best suited to your plant. For this purpose computer calculated frequency analyses can be requested from YORK Refrigeration for the compressor unit in question. Another and very efficient solution would be to noise insulate the compressor unit itself. YORK Refrigeration is able to deliver pre-fabricated and tested noise baffle boards. Fig. 6.58

In General The following paragraphs include a description of the factors that influence the acoustic quality of a machine room.

Reverberation Time
By a correct application of noise absorbing materials it is possible to change the reverberation time of a machine room which is defined as the time it takes for the sound pressure level Lp to drop 60 dB once the noise source stops. The duration of the reverberation time depends on the volume of the room as well as the average absorption coefficient for the noise absorbing materials that are fitted in the room as they should be. Absorption Coefficient Usually the absorption coefficient for noise absorbing materials is 0.5 to 0.8. See the following illustration, Fig. 6.59. Fig. 6.59
Noise damping material Incident sound power

06 technical data.fm

Absorbed sound power

Transmitted sound power

X=

Reflected sound power Incident sound power

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Subjective Perception of Noise Damping With reference to table, Table 6.14, indicating how the human ear perceives the effect of noise insulation in a machine room, the following should be noted: By investing in a sensible noise insulation of the ceiling of the machine room this usually means reducing the reverberation time by

half in the machine room with a subsequent great subjective effect. When using a pre-fabricated noise baffle board from YORK Refrigeration, the sound pressure in the machine room will typically be reduced by 20 dB. Naturally, this must be considered a great improvement - subjectively perceived.

Table 6.14
Reduction of sound pressure by noise insulation of compressor unit dB 0 1 3 6 10 20 * Reduction of the average sound pressure level by noise insulation dB 0 0,5 1 2 3 6 Relative reverberation time 1 0,9 0,8 0,6 0,5 0,25 Insignificant Perceivable Distinct Considerable Very considerable Subjective perception of the improved acoustic quality of the room

*The YORK Refrigeration prefabricated Version 2.0 noise baffle board for compressor units

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Vibration Data for Compressors - All Compressor Types


Vibration data for YORK Refrigeration's Sabroe reciprocating compressors comply with: the ISO 10816, standard, Part 6, Annex A, group 4, AB, which fixes max. permissible operating vibrations at 17.8 mm/s. Vibration data for YORK Refrigeration's Sabroe screw compressors comply with: ISO 10816 Fig. 6.60
CV AV BV AA xAH BH x BA CA x CH DHx DA DV

standard, part 1, Annex B, Class III, C, which fixes max. permissible operating vibrations at 11.2 mm/s. The measurements are made as illustrated in the figure below (points A-D).

06 technical data.fm Pay attention to the following, however: Motors comply with EN 60034-14 (CEI/IEC 34-14) Class N. When placing the unit on the vibration dampers supplied by YORK Refrigeration (additional), the vibrations against the foundation are reduced by: 85-95% for screw compressor units 80% for reciprocating compressor units However, higher vibration level may occur if: motor and compressor have not been aligned as described in the Instruction Manual. the compressor runs at an incorrect Vi ratio. This applies to screw compressors. the piping connections have been executed in a way that makes them force pull or push powers on the compressor unit or transfer vibrations to the unit caused by natural vibrations or connected machinery. the vibration dampers have not been fitted or loaded correctly as indicated in the foundation drawing accompanying the order.

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Fig. 6.61

Specification of Compressor Materials sistance to the refrigerants and oils approved for the compressors. The following table,Table 6.15, lists the most important components.

The materials to be used for the individual components of the compressors have been selected in view of a long life, wear resistance as well as re-

Table 6.15
Designation Compressor frame SMC and TSMC Compressor frame HPC 100 Oil pump housing HPC 100, SMC and TSMC100 Bearing cover pump end HPC 100, SMC and TSMC100 Water covers HPC 100, SMC and TSMC100 All other covers SMC and TSMC All other covers HPC Crankshaft HPC108 Crankshaft all other compressors Connecting rod Piston pin bushing Half section of bearings for Connecting rod Bolts for connecting rod Piston Piston rings and oil scraper ring Piston pin Cylinder liners Suction and discharge valve plates Suction valve retaining plate Safety head spring Main bearings Shaft seal carbon ring Shaft seal steel ring Suction filter Oil level glass Oil strainer By-pass valve Buffer springs Gaskets O-ring seals Material Cast iron Ductile cast iron Cast iron Ductile cast iron Cast iron Cast iron Ductile cast iron Ductile cast iron Ductile cast iron Ductile cast iron Phosphor bronze White metal on a steel base Cr-Mo steel Aluminium alloy Cast iron Cr-steel Cast iron w/special heat treatment Special steel Ductile cast iron Steel spring White metal on a steel base Special carbon Special steel Stainless steel wire-mesh Glass in steel flange Filter cartridge Various steel Spring steel Non-asbestos CR Rubber (standard) EN-GJS-600-3, EN 1563 54SiCr6, DIN 17221 Form EN-GJL-250, EN 1561 EN-GJS-500-7, EN 1563 EN-GJL-250, EN 1561 EN-GJS-500-7, EN 1563 EN-GJL-250, EN 1561 EN-GJL-250, EN 1561 EN-GJS-500-7, EN 1563 EN-GJS-800-2, EN 1563 EN-GJS-700-2, EN 1563 EN-GJS-700-2, EN 1563 BS1400, PB1-C

Cl, 12.9, DIN 898 BS 1490/LM13 BS 1452 (W.CI7) 17Cr3, DIN 17210 EN-GJL-250, EN 1561

A62P AISI 316 AISI 304 C75, DIN 17222

Compound 2347

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6. Technical Data

Test Pressure Levels for Standard Compressors and Components


All components for refrigeration plants which are under the influence of gas pressure must be pressure tested to prove their strength and tightness. The approving authorities determine the test pressure levels on the basis of various criteria. However, the test pressure requirements can be summarized into a number of standard pressure levels which in practice meet the requirements set up, and which can therefore be approved by all authorities involved. The following table, Table 6.16, shows the standard pressure levels used by YORK Refrigeration. In case of specific applications, the authorities may, however, demand a higher test pressure level. Within certain limits such requirements can be met for SABROE compressors - against an addiTable 6.16
Standard Test Pressure Levels
Compressor Type CMO SMC 100 SMC 180 Compressor Side bar High pressure side Low pressure side High pressure side TCMO TSMC HPO HPC SAB 110 SAB 128 SAB 163 SAB 202 SAB 283L/E SAB 355 L Compressor Unit Vessels in general All types The entire unit Individual pressure testing in accordance with the local rules and regulations. Consequently, no table can be set up. Low pressure side Intermediate pressure side High pressure side Low pressure side 42 27 42 27 42 80 45 Strength Testing [psi] [609] [392] [609] [392] [609] [1160] [653] Leak Testing with Pressurized Air bar 25 14 25 14 25 40 22 [psi] [363] [203] [363] [203] [363] [580] [319]

tional price. Please, contact YORK Refrigeration for further information. When pressure testing compressors and vessels, components must first prove their strength by resisting the test pressure of the strength test. This test is carried out with air. Afterwards, the leak test is carried out, also with air, at the prescribed pressure and with the component soaked in a water basin for 30 minutes. Units consist of components which have been pressure tested as described in the following table. This means that it is only necessary to leak test the unit. Dwelling time is 20 minutes. Leak testing is carried out with pressurized air at the pressure stated in the table. All weldings and connections are covered with a frothing liquid which will start foaming in case of a leak.

06 technical data.fm

The entire compressor block

42

[609]

21

[305]

39

[566]

26 7

[377] [102]

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6. Technical Data

Charging the Compressor with Oil


Usually, the compressor is delivered without any oil in the crankcase. As a principal rule, the amount of oil indicated in the table, Table 6.17, should be charged to the compressor. Table 6.17 Oil Charging
Amount of oil in crankcase Liter 26 28 30 47 50 US gal. 6.9 7.4 7.9 12.4 13.2
T0177162_0

Fig. 6.62

Oil level glass

10 mm

Compressor Type HPC 100 SMC 100 TSMC 100 Mk 4 S-L-E Size 104 106 108 112 116

Table 6.18
Compressor Type HPC 100 SMC 100 TSMC 100 S-L-E Size 104 106 108 112 116 Difference in oil level of 10 mm corresponds to: - 2 litres of oil [0.5 US gal.] - 6 litres of oil [1.6 US gal.]

After some hours of operation the compressor must be recharged with oil, however, as part of the oil has been absorbed by the refrigerant. This is especially the case for HFC and HCFC refrigerants. The amount of oil to be recharged depends on the size of the refrigeration plant and the amount of refrigerant. Oil is charged to the middle of the oil level glass and the amount of oil needed in order to increase the oil level 10 mm is indicated in the table, Table 6.18.

A manually operated pump connected to the oil charging valve pos. B can be used for the first as well as the following oil charges. See Section 5, Physical and Connection Data. Note: On HPC 100 compressors with R717, the pressure must be relieved before oil charging. Fig. 6.63 Manually Operated Oil Pump
Optional hand-operated oilpump

To compressor

Gasket B

Cap

T0177131_0V

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Oil Consumption
In refrigeration compressors there will always be a minor oil consumption, which means that a little oil is bound to follow the warm discharge gas out of the compressor. In order to separate this oil, an oil separator is normally used. The separator is built into the discharge pipe, right next to the compressor. The separated oil is returned to the compressor as described in Section 4, Technical Description - Oil Separator. A minor part of the oil, however, present in the discharge gas as vapour, cannot be separated and will consequently continue into the plant, in which it is condensed in the condenser. In HFC and HCFC as well as in compact R717 refrigeration plants this oil will return to the compressor together with the suction gas. In return, the oil in larger and ramified R717 refrigeration plants should be drained off and never reused in the compressor. This amount of oil represents the so-called oil consumption measured in ppm. Ppm is the abbreviation for parts per million and is calculated by using the following formula:

Oil consumption kg/h =

Circulated amount of refrigerant Q (kg/h) x Oil consumption (ppm) 10


6

06 technical data.fm

The normal oil consumption is between 20 and 30 ppm for an SMC/HPC 100 compressor.

Selecting Oil Separator


As the velocity through the oil separator affects the ability of the oil separator to separate the oil from the discharge gas, an oil separator size has been designed for each compressor. See Table 6.19. The maximum oil consumption for this oil separator is 35 ppm. Depending on the choice of lubricating oil, the oil consumption is normally much lower.

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Table 6.19
Code no.

Oil Separators
Part no. 4241.280 4241.280 4241.280 4241.280 4241.280 4241.280 4241.280 4241.280 4241.281 4241.280 4241.280 4241.280 4241.281 4241.280 4241.280 4241.280 4241.281 4241.280 4241.280 4241.280 4241.281 4241.280 4241.281 4241.281 4241.342 4241.281 4241.281 4241.281 4241.342 4241.281 4241.281 4241.281 4241.282 4241.342 4241.281 4241.281 4241.281 4241.282 4241.342 4241.281 Type OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 4107D OVUR 3206D OVUR 4107D OVUR 4107D OVUR 5008 HP OVUR 4107D OVUR 4107D OVUR 4107D OVUR 5008 HP OVUR 4107D OVUR 4107D OVUR 4107D OVUR 6006D OVUR 5008 HP OVUR 4107D OVUR 4107D OVUR 4107D OVUR 6006D OVUR 5008 HP OVUR 4107D Refr.

SMC 104S - B301 SMC 104L - B301 SMC 104E - B301 SMC 104S - B302 SMC 104L - B302 SMC 104E - B302 SMC 106S - B301 SMC 106L - B301 SMC 106E - B301 SMC 106E - B314 SMC 106S - B302 SMC 106L - B302 SMC 106E - B302 SMC 106E - B315 SMC 108S - B301 SMC 108L - B301 SMC 108E - B301 SMC 108E - B314 SMC 108S - B302 SMC 108L - B302 SMC 108E - B302 SMC 108E - B315 SMC 112S - B301 SMC 112L - B301 SMC 112E - B305 SMC 112E - B314 SMC 112S - B302 SMC 112L - B302 SMC 112E - B308 SMC 112E - B315 SMC 116S - B301 SMC 116L - B301 SMC 116E - B301 SMC 116E - B305 SMC 116E - B314 SMC 116S - B302 SMC 116L - B302 SMC 116E - B302 SMC 116E - B308 SMC 116E - B315

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Code no. TSMC 108S-B301 TSMC 108L-B301 TSMC 108E-B301 TSMC 108S-B311 TSMC 108L-B311 TSMC 108E-B311 TSMC 108S-B302 TSMC 108L-B302 TSMC 108E-B302 TSMC 108S-B312 TSMC 108L-B312 TSMC 108E-B312 TSMC 116S-B301 TSMC 116L-B301 TSMC 116E-B301 TSMC 116S-B311 TSMC 116L-B311 TSMC 116E-B311 TSMC 116S-B302 TSMC 116L-B302 TSMC 116E-B302 TSMC 116S-B312 TSMC 116L-B312 TSMC 116E-B312

Part no. 4241.279 4241.279 4241.279 4241.279/4241.280 4241.279/4241.280 4241.279/4241.280 4241.279 4241.279 4241.279 4241.279/4241.280 4241.279/4241.280 4241.279/4241.280 4241.280 4241.280 4241.280 4241.280/4241.281 4241.280/4241.281 4241.280/4241.281 4241.280 4241.280 4241.280 4241.280/4241.281 4241.280/4241.281 4241.280/4241.281

Type OVUR 2106D OVUR 2106D OVUR 2106D OVUR 2106D/OVUR 3206D OVUR 2106D/OVUR 3206D OVUR 2106D/OVUR 3206D OVUR 2106D OVUR 2106D OVUR 2106D OVUR 2106D/OVUR 3206D OVUR 2106D/OVUR 3206D OVUR 2106D/OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D/OVUR 4107D OVUR 3206D/OVUR 4107D OVUR 3206D/OVUR 4107D OVUR 3206D OVUR 3206D OVUR 3206D OVUR 3206D/OVUR 4107D OVUR 3206D/OVUR 4107D OVUR 3206D/OVUR 4107D

Refr.

06 technical data.fm

For the E - version the following special conditions apply (TE = evaporating temperature):
SMC 104E: SMC 106E: SMC 108E: SMC 112E: SMC 112E: OVUR 3206D OVUR 3206D (TE<+15C) [+59F] OVUR 4107D (TE>+15C) [+59F] OVUR 3206D (TE<+5C) [+41F] OVUR 4107D (TE>+5C) [+41F] OVUR 4107D (TE<+10C) [+50F] OVUR 5008D (TE>+10C) [+50F OVUR 4107D (TE<0C) [+32F] OVUR 5008D (0C<TE<+20C) [+32F<TE<+68F] OVUR 6006D (TE>+20C) [+68F]

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Selecting Lubricating Oil for SABROE Reciprocating Compressors Refrigerant: R717


In a period from 1990 to 1995 YORK Refrigeration experienced a rising number of problems with the use of mineral oils, especially in R717 plants. The problems can be divided into two groups: c. d. The oil changes viscosity within a few operating hours. The oil dissolves (becomes very black). General This recommendation will only deal with the lubrication of the compressor. The performance of the lubricant in the plant (receiver, evaporator, etc.) must, however, also be considered. Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of refrigeration compressors. To achieve the best lubrication, the oil must: possess the correct viscosity under all operating conditions. possess acceptable viscosity at start-up. possess sufficient oxidation stability (the oil must be free of moisture when charged to the system). possess sufficient chemical stability when used together with R717.

The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours. The consequences have been severe for both compressors and plants. On the basis of the thorough investigation subsequently carried out by YORK Refrigeration, it was decided to introduce a series of synthetic oils complying with the requirements of modern refrigeration plants. Mineral oils can, however, still be used in refrigeration plants, provided the lubricating quality is carefully monitored. For modern high-capacity refrigeration plants where a long service life for both lubricant and moving parts is expected, YORK Refrigeration recommends the use of synthetic oils. Areas of application and specifications for the synthetic oils mentioned are described in the following pages. Supervisors and/or users of plants are at liberty to choose between YORK Refrigeration's own oil brands and alternative oil brands, provided they comply with the specifications required.

Moreover, the extent to which different refrigerants dissolve in the oil must be determined so that the oil return system, etc. can be designed to perform at its optimum. Stratification Note that the oil in some plants is layered in refrigerant receivers and evaporators under certain operating conditions and at certain oil concentrations. Plants with Several Different Compressor Types/Makes In plants where several different compressor types/makes are connected, it is strongly recommended to use the same type of oil in all the compressors. This is very important where automatic oil return systems are used.

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If you consider changing the type of oil, please read the section Oil Changing on SABROE Compressors carefully. Selecting Lubricating Oil The correct oil is selected by means of the following diagrams. When the general conditions concerning the lubrication of the compressor have been considered, the specific conditions of the plant must be taken into account. Use the oil recommendation diagrams to select the correct oil code number. The oil code number consists of letters indicating the oil type and viscosity number. Table 6.20
Code design Oil types Mineral oil Synthetic oil based on Alkylbenzene Synthetic oil based on Polyalphaolefin Mixture of A and PAO oils Synthetic ester-based lubricants

mation on this beforehand from the oil company. This makes it extremely difficult for YORK Refrigeration to give a general approval of other oil brands. In co-operation with a large, respected oil company YORK Refrigeration has therefore developed a series of three different oils covering most demands. Furthermore, a list of the oils which can be supplied through YORK Refrigeration has been prepared. Data for these oils is included in the table Data for Sabroe Oils. We recommend that you use these oils, which can be delivered in 20 litre pails or 208 litre drums. When ordering, use the part no. stated in List of Part Numbers for Available Sabroe Oils. It is of course possible to use similar oils from other oil companies. If this is the case, use the table Data for Sabroe Oils. Please note that YORK Refrigeration has not tested other oils than our own brand. Thus we cannot guarantee the quality, stability or suitability of other oils. The respective oil companies are thus responsible for the quality and suitability of the oil delivered, and if there are any problems with these oils in the compressor or the refrigeration plant, contact the oil supplier directly. When selecting oils from other oil companies, special attention should be paid to the suitability of the oil in the compressor and the refrigeration plant as a whole. Please note in particular the following points: Oil type Compressor type Miscibility between refrigerant and oil Operating data for the compressor Discharge gas temperature Oil temperature

06 technical data.fm

M A PAO AP E

In the oil recommendation diagrams it is possible to find the code number best suited for the operating conditions in question. With the code number it is possible to select the correct Sabroe oil for the application in question. Oil Types and Oil Companies Due to the large number of oil companies offering oil for refrigeration plants, it has not been possible for YORK Refrigeration to test all the different oil brands on the global market. It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery. We have thus experienced changes in specifications as well as formula and performance without having received infor-

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Normal oil temperature in crankcase is 50-60C Max. permitted oil temperature = set point for alarm Min. permitted oil temperature = set point for alarm - if there is any The viscosity of the oil in the compressor during operation: Type of refrigerant and solubility of refrigerant in the oil Operating temperatures Vapour pressure in the oil reservoir Suction pressure and oil temperature in the crankcase Compatibility with neoprene O-rings: The aniline point indicates how the Oring material reacts to the oil. At an aniline point less than approx. 100C the material has a tendency to swell, and at an aniline point higher than approx. 120C it has a tendency to shrink Thus it cannot be recommended to change the oil type from M to PAO without changing the O-rings at the same time as a leak may otherwise easily occur in the compressor or the plant. YORK Refrigeration recommends therefore the use of the Sabroe AP68 oil since this type of oil in this case reduces considerably the risk of leaks. YORK Refrigeration can supply a list of operating data on request. Please note the viscosity limits during operation: Optimum viscosity limits = 20 to 50 cSt

Max. permitted viscosity = 100 cSt Min. permitted viscosity = 10 cSt Max. permitted viscosity during startup of the compressor = 500 cSt Max. refrigerant concentration in the oil during operation: 25% - also in case the viscosity requirements have been met. Use of Mineral Oil As described in the introduction, mineral oil in particular causes serious problems especially in R717 plants. When using mineral oil, it is important to monitor the plant closely. The condition/colour of the oil must therefore be checked on a weekly basis and for each 1,000 to 2,000 operating hours oil samples must be taken for further analysis. YORK Refrigeration recommends therefore only to use M oil under moderate operating conditions - see the following oil recommendation diagrams. YORK Refrigeration is aware that several customers have used mineral oils for many years without any problems. The customers who wish to continue using mineral oil in existing as well as new compressors can do so, provided that the compressor type and the operating conditions are similar to the existing ones. YORK Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refrigeration purposes. In case another brand of mineral oil is used, follow the specifications on the data pages in this recommendation as a guideline. Mineral oil can be used in refrigeration plants, provided the lubricating quality is carefully monitored. YORK Refrigeration recommends, however, that

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you use synthetic oils for modern high-capacity plants where a long service life for both lubricant and moving parts is expected. The advantage of using synthetic lubricating oils is a much lower oil consumption and longer oil changing intervals. Improved viscosity at low temperatures facilitates furthermore drainage at the cold parts of the plants. How to Use the Diagrams in the Oil Recommendation: To find the correct code number, select refrigerant and compressor type in the oil recommendation diagram. Then insert the estimated operating conditions in the diagram. Example (reciprocating compressors): R717 Refrigerant Condensing temperature: TC +35 C Evaporating temperature: TE -20 C Note: Sometimes plants operate under different conditions, e.g. different evaporating temperatures due to variations in the plant, or different condensing temperatures as a result of seasonal changes. By inserting TC and TE in the oil recommendation diagram, the recommended area is found. In this case it is oil area 1. If the intersection is outside the area, contact YORK Refrigeration for a detailed calculation by means of the calculation program COMP1.

Fig. 6.64
TC
F 122 104 86 68 50 32 C 50 40 30 20 10 0

14 -10 -4 -20

-22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 C F

TE

06 technical data.fm

By using the table which is situated next to the oil recommendation diagram, select the recommended code number and thus the recommended oil. In the example above there are thus 3 possibilities: PAO3, AP1 or M1. However, M1 is only recommended for moderately loaded compressors. Table 6.21
Code no. PAO3 AP1 M1 Area no. 1

/
See note

Oil Change on Sabroe Compressors Never change to another oil type without contacting the oil supplier. Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in question. Mixing different oils may result in operating problems in the refrigeration plant or damage to the compressor. Incompatibility between different oil types may reduce the lubricating properties considerably and may cause oil residues to form in the compressor, oil separator or plant. Oil resi-

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dues may block filters and damage the moving parts of the compressor. Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant. Information on a suitable procedure can be obtained from YORK Refrigeration as well as a number of oil companies. It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant.

Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil. Many oils, particularly polyolester oils, are extremely hygroscopic. It is therefore recommended only to buy the oil in containers whose size correspond to the amount to be used. In case all of the oil is not used, make sure that the rest of the oil is sealed in the original container and stored in a warm, dry place. It is recommended to charge nitrogen to keep the water content below 50 ppm. Ideally, oil containers should be equipped with a barrel tap to ensure an effective, airtight seal.

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Oil Changing Intervals A list of the recommended oil changing intervals is included in the instruction manuals of the compressors. This list is for guidance only. The actual oil changing intervals are often determined by a number of operating parameters in the plant. Oil recommendation diagram symbols:

It is strongly recommended to monitor the quality of the oil by performing oil analyses on a regular basis. This will also give an indication of the condition of the plant. This service can be supplied by YORK Refrigeration or the oil supplier.

In case of a new plant. Very suitable. In case you wish to change from mineral oil Max oil concentration in liquid phase at: TE: 2% W Max oil concentration in liquid phase: contact YORK Refrigeration Min. suction temperature -50C. At TE< -50C superheating must be introduced. Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

a b c * SH

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L M

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Data Sheet for Listed Sabroe Oils Typical data for lubricating oils for Sabroe compressors
Sabroe code M1 A3 AP1 PAO3 PAO5 PAO9 E3 E5 E9 E11 Due to the great difference between polyolester-based lubricants from various suppliers, it is not possible to present any typical data for these oils. When using another oil brand than the one recommended by YORK Refrigeration, please contact the oil supplier to select the correct oil type. Viscosity cSt 40C 63 97 64 66 94 208 cSt 100C 6.4 8.1 9.3 10.1 13.7 25 Viscosity Index 14 13 121 136 147 149 Spec. grav. at 15C 0.91 0.86 0.858 0.835 0.838 0.846 Flash p. COC C 202 206 195 266 255 260 Pour p. Anilin Acid no. mg KOH/g 0.02 0.05 0.04 0.03 0.03 0.03

C
-36 -32 -51 <-45 <-45 <-39

C point
81 78 121 138 144 154

The listed data are typical values and are only intended as a guideline when selecting a similar oil from a different oil company. Data equivalence does not necessarily qualify the oil for use in YORK Refrigeration's Sabroe compressors.

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List of Part Numbers for Available Sabroe Oils


Oil brand Mobil Gargoyle Arctic 300 Sabroe Oil A100 Sabroe Oil AP68 Sabroe Oil PAO68 Mobil Gargoyle Arctic SHC 228 Mobil Gargoyle Arctic SHC 230 Mobil EAL Arctic 68 Mobil EAL Arctic 100 Mobil EAL Arctic 220 Sabroe H oil
1)

Oil code no. 20 litre pail M1 (M68) A3 (A100) AP1 (AP68) PAO3 (P68) PAO5 (P100) PAO9 (P220) E3 (E68) E5 (E100) E9 (E220) E11 (E370) 3914 1512 954 1231-264 1231-263 1231-257 1231-256 1231-282 1231-284 1231-272 1231-274

Part no. 208 litre barrel 1231-296 1231-262 1231-260 1231-259 1231-283 1231-285 1231-273 1231-275 1231-279
1)

9415 0008 000

18.9 litre pail (5 US gallons)

06 technical data.fm

The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type A B C H Sabroe oil Mobil Gargoyle Arctic 300 - M1 (M68) Sabroe Oil PAO 68 - PAO 3 (PAO 68) Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220) Sabroe H oil - E 11 (E 370)

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R717
one-stage reciprocating compressor
Condensing temperature
F

TC
C

122 50 104 40 86 68 50 32 30 20 10 0

14 -10 -4 -20 -22 -30 -60 -76 -50 -58 -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

C F

TE

Evaporating temperature Code no PAO 3 AP 1 M1 Area no 1 s

/
See note

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. j: : Very suitable in case of a new plant. In case you wish to change from mineral oil.

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R717
two-stage reciprocating compressors
Condensing temperature
F

TC
C

122 50 104 40 86 30 68 50 32 20 10 0

14 -10 -4 -20

06 technical data.fm

-22 -30 -60 -76 -50 -58 -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

C F

TE

Evaporating temperature Code no PAO 3 AP 1 M1 Area no 1 s

/
See note

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. j: : Very suitable in case of a new plant. In case you wish to change from mineral oil.

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R717
HPO and HPC reciprocating compressors
Condensing temperature

TC
F C

176 80 158 70 140 60 122 50 104 40 86 30 68 20 50 10 32 0 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 30 86 40 104 50 122 C F

TE

Evaporating temperature

Code no PAO 5

Area no 1

Note: Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors j: Very suitable in case of a new plant.

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List of Major Oil Companies


The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not approved by YORK Refrigeration. The following list includes the information provided by the oil companies. The oil companies are responsible for the information concerning the durability and suitability of their oils for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part Numbers for Available Sabroe Oils".
Oil Company M A Oil Types PAO AP E

Aral Avia BP Castrol Chevron (UK: Gulf Oil) CPI Engineering Services DEA Elf / Lub Marine 1 Esso/Exxon Fina Fuchs Hydro-Texaco ICI Kuwait Petroleum (Q8) Mobil Petro-Canada Shell Statoil Sun Oil

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Selecting Lubricating Oil for SABROE Reciprocating Compressors Refrigerant: HFC/HCFC


In a period from 1990 to 1995 YORK Refrigeration experienced a rising number of problems with the use of mineral oils, especially in R717 plants. The problems can be divided into two groups: e. f. The oil changes viscosity within a few operating hours. The oil dissolves becomes very black). lubricant in the plant (receiver, evaporator, etc.) must, however, also be considered. Lubricating oils with relatively high viscosity must be used to ensure a satisfactory lubrication of refrigeration compressors. To achieve the best lubrication, the oil must: possess the correct viscosity under all operating conditions. possess acceptable viscosity at start-up. possess sufficient oxidation stability (the oil must be free of moisture when charged to the system). possess sufficient chemical stability when used together with HFC/HCFC.

The problems have been observed in connection with several different types of mineral oil and often occur within only a few operating hours. The consequences have been severe for both compressors and plants. On the basis of the thorough investigation subsequently carried out by YORK Refrigeration, it was decided to introduce a series of synthetic oils complying with the requirements of modern refrigeration plants. Mineral oils can, however, still be used in refrigeration plants, provided the lubricating quality is carefully monitored. For modern high-capacity refrigeration plants where a long service life for both lubricant and moving parts is expected, YORK Refrigeration recommends the use of synthetic oils. Areas of application and specifications for the synthetic oils mentioned are described in the following pages. Supervisors and/or users of plants are at liberty to choose between YORK Refrigeration's own oil brands and alternative oil brands, provided they comply with the specifications required. General This recommendation will only deal with the lubrication of the compressor. The performance of the

Moreover, the extent to which different refrigerants dissolve in the oil must be determined so that the oil return system, etc. can be designed to perform at its optimum. Stratification Note that the oil in some plants is layered in refrigerant receivers and evaporators under certain operating conditions and at certain oil concentrations. This applies in particular to HFC/HCFC plants. The oil recommendation diagrams for SABROE compressors with HFC and HCFC refrigerants indicate the limits for Sabroe oils where stratification occurs. The oil concentrations stated in these diagrams must not be exceeded. This makes it possible to adjust the oil rectification/return systems to the oil consumption of the compressor so that the maximum concentration is not exceeded. For area A in the diagrams, the oil concentration in the liquid phase must not exceed 2%. For the other

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areas, the oil concentration must not exceed 5%. For area B, please contact YORK Refrigeration. Plants with Several Different Compressor Types/Makes In plants where several different compressor types/makes are connected, it is strongly recommended to use the same type of oil in all the compressors. This is very important where automatic oil return systems are used. If you consider changing the type of oil, please read the section Oil Changing on SABROE Compressors carefully. Selecting Lubricating Oil The correct oil is selected by means of the following diagrams. When the general conditions concerning the lubrication of the compressor have been considered, the specific conditions of the plant must be taken into account. Use the oil recommendation diagrams to select the correct oil code number. The oil code number consists of letters indicating the oil type and viscosity number.. Table 6.22
Code design M A PAO AP E Oil types Mineral oil Synthetic oil based on Alkylbenzene Synthetic oil based on Polyalphaolefin Mixture of A and PAO oils Synthetic ester-based lubricants

Oil Types and Oil Companies Due to the large number of oil companies offering oil for refrigeration plants, it has not been possible for YORK Refrigeration to test all the different oil brands on the global market. It is our experience that certain oil brands can change character during use and thus no longer correspond to the specifications stated by the oil companies on delivery. We have thus experienced changes in specifications as well as formula and performance without having received information on this beforehand from the oil company. This makes it extremely difficult for YORK Refrigeration to give a general approval of other oil brands. In co-operation with a large, respected oil company YORK Refrigeration has therefore developed a series of three different oils covering most demands. Furthermore, a list of the oils which can be supplied through YORK Refrigeration has been prepared. Data for these oils is included in the table Data for Sabroe Oils. We recommend that you use these oils, which can be delivered in 20 litre pails or 208 litre drums. When ordering, use the part no. stated in List of Part Numbers for Available Sabroe Oils. It is of course possible to use similar oils from other oil companies. If this is the case, use the table Data for Sabroe Oils. Please note that YORK Refrigeration has not tested other oils than our own brand. Thus we cannot guarantee the quality, stability or suitability of other oils. The respective oil companies are thus responsible for the quality and suitability of the oil delivered, and if there are any problems with these oils in the compressor or the refrigeration plant, contact the oil supplier directly. When selecting oils from other oil companies, special attention should be paid to the suitability of

06 technical data.fm

In the oil recommendation diagrams it is possible to find the code number best suited for the operating conditions in question. With the code number it is possible to select the correct Sabroe oil for the application in question.

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the oil in the compressor and the refrigeration plant as a whole. Please note in particular the following points: Oil type Refrigerant type Compressor type Miscibility between refrigerant and oil Operating data for the compressor Discharge gas temperature Oil temperature Normal temperature in the crank case is 50-60C Max. permitted oil temperature = set point for alarm. Min. permitted oil temperature = set point for alarm - if there is any The viscosity of the oil in the compressor during operation and under the influence of: Type of refrigerant and solubility of refrigerant in the oil Operating temperatures Vapour pressure in the oil reservoir Suction pressure and oil temperature in the crankcase Compatibility with neoprene O-rings: The aniline point indicates how the O-ring material reacts to the oil. At an aniline point less than approx. 100C the material has a tendency to swell, and at an aniline point higher than approx. 120C it has a tendency to shrink. Thus it cannot be recommended to change the oil type from M to PAO without changing the O-rings at the same time as a leak may otherwise easily occur in the compressor or

the plant. YORK Refrigeration recommends therefore the use of the Sabroe AP68 oil since this type of oil in this case reduces considerably the risk of leaks. YORK Refrigeration can supply a list of operating data on request. Please note the viscosity limits during operation: Optimum viscosity limits = 20 to 50 cSt Max. permitted viscosity = 100 cSt Min. permitted viscosity = 10 cSt Max. permitted viscosity during startup of the compressor = 500 cSt Max. refrigerant concentration in the oil during operation: 25% - also in case the viscosity requirements have been met. Use of Mineral Oil As described in the introduction, mineral oil in particular causes serious problems especially in R717 plants. When using mineral oil, it is important to monitor the plant closely. The condition/colour of the oil must therefore be checked on a weekly basis and for each 1,000 to 2,000 operating hours oil samples must be taken for further analysis. YORK Refrigeration recommends therefore only to use M oil under moderate operating conditions - see the following oil recommendation diagrams. YORK Refrigeration is aware that several customers have used mineral oils for many years without any problems. The customers who wish to continue using mineral oil in existing as well as new compressors can do so, provided that the compressor type and the operating conditions are similar to the existing ones.

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YORK Refrigeration has thus decided to market one brand of mineral oil which has been tested and found suitable for most of the general refrigeration purposes. In case another brand of mineral oil is used, follow the specifications on the data pages in this recommendation as a guideline. Mineral oil can be used in refrigeration plants, provided the lubricating quality is carefully monitored. YORK Refrigeration recommends, however, that you use synthetic oils for modern high-capacity plants where a long service life for both lubricant and moving parts is expected. The advantage of using synthetic lubricating oils is a much lower oil consumption and longer oil changing intervals. Improved viscosity at low temperatures facilitates furthermore drainage at the cold parts of the plants. How to Use the Diagrams in the Oil Recommendation: To find the correct code number, select refrigerant and compressor type in the oil recommendation diagram. Then insert the estimated operating conditions in the diagram. Example (reciprocating compressors): R134a Refrigerant Condensing temperature: TC +35 C Evaporating temperature: TE -3C Note: Sometimes plants operate under different conditions, e.g. different evaporating temperatures due to variations in the plant, or different condensing temperatures as a result of seasonal changes. By inserting TC and TE in the oil recommendation diagram, the recommended area is found. In this case it is oil area 1. If TC should change, e.g. from -3C to +7C, use oil area 2. As +7C is within the marked area, oil area 1 can, however, also be used at this TE.

Fig. 6.65
R134a
TC

F C
158 70 140 60 122 50 Condensing temperature 104 40 86 30 68 20 50 10 32 0

w w

14 10 4 20

22 30 60 76 50 40 58 40 30 20 10 0 10 20 30 C

4 14 32 50 68 86 F 22 Evaporating temperature

TE

06 technical data.fm

By using the table which is situated next to the oil recommendation diagram, select the recommended code number and thus the recommended oil. In the example above an oil with code number E5 can be used. Table 6.23
Code no. Area no. 1 E5 E9 2

Oil Change on Sabroe Compressors Never change to another oil type without contacting the oil supplier. Nor is it advisable to recharge a compressor with another oil type than the one already used for the plant or compressor in question. Mixing different oils may result in operating problems in the refrigeration plant or damage to the compressor. Incompatibility between different oil types may reduce the lubricating properties considerably and may cause oil residues to form in

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6. Technical Data

the compressor, oil separator or plant. Oil residues may block filters and damage the moving parts of the compressor. Changing the oil type or brand should only be done following a thorough procedure involving drainage and evacuation of the refrigeration plant. Information on a suitable procedure can be obtained from YORK Refrigeration as well as a number of oil companies. It is extremely important that the new unused oil is taken directly from its original container and that both the brand and the type correspond to the specifications of the plant.

Make sure that the original oil container is sealed properly during storage so that moisture from the air is not absorbed by the oil. Many oils, particularly polyester oils, are extremely hygroscopic. It is therefore recommended only to buy the oil in containers whose size correspond to the amount to be used. In case all of the oil is not used, make sure that the rest of the oil is sealed in the original container and stored in a warm, dry place. It is recommended to charge nitrogen to keep the water content below 50 ppm. Ideally, oil containers should be equipped with a barrel tap to ensure an effective, airtight seal.

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6. Technical Data

Oil Changing Intervals


A list of the recommended oil changing intervals is included in the instruction manuals of the compressors. This list is for guidance only. The actual oil changing intervals are often determined by a number of operating parameters in the plant. Oil recommendation diagram symbols:

It is strongly recommended to monitor the quality of the oil by performing oil analyses on a regular basis. This will also give an indication of the condition of the plant. This service can be supplied by YORK Refrigeration or the oil supplier..

In case of a new plant. Very suitable. In case you wish to change from mineral oil Max oil concentration in liquid phase at: TE: 2% W Max oil concentration in liquid phase: contact YORK Refrigeration Min. suction temperature -50C. At TE< -50C superheating must be introduced. Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

a b c * SH

06 technical data.fm

L M

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6. Technical Data

Data Sheet for Listed Sabroe Oils Typical data for lubricating oils for Sabroe compressors
Sabroe code M1 A3 AP1 PAO3 PAO5 PAO9 E3 E5 E9 E11 Due to the great difference between polyolester-based lubricants from various suppliers, it is not possible to present any typical data for these oils. When using another oil brand than the one recommended by YORK Refrigeration, please contact the oil supplier to select the correct oil type. Viscosity cSt 40C 63 97 64 66 94 208 cSt 100C 6.4 8.1 9.3 10.1 13.7 25 Viscosity Index 14 13 121 136 147 149 Spec. grav. at 15C 0.91 0.86 0.858 0.835 0.838 0.846 Flash p. COC C 202 206 195 266 255 260 Pour p. Anilin Acid no. mg KOH/g 0.02 0.05 0.04 0.03 0.03 0.03

C
-36 -32 -51 <-45 <-45 <-39

C point
81 78 121 138 144 154

The listed data are typical values and are only intended as a guideline when selecting a similar oil from a different oil company. Data equivalence does not necessarily qualify the oil for use in YORK Refrigeration's Sabroe compressors.

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6. Technical Data

List of Part Numbers for Available Sabroe Oils


Oil brand Mobil Gargoyle Arctic 300 Sabroe Oil A100 Sabroe Oil AP68 Sabroe Oil PAO68 Mobil Gargoyle Arctic SHC 228 Mobil Gargoyle Arctic SHC 230 Mobil EAL Arctic 68 Mobil EAL Arctic 100 Mobil EAL Arctic 220 Sabroe H oil Oil code no. 20 litre pail M1 (M68) A3 (A100) AP1 (AP68) PAO3 (P68) PAO5 (P100) PAO9 (P220) E3 (E68) E5 (E100) E9 (E220) E11 (E370) 3914 1512 954
1)

Part no. 208 litre barrel 1231-296 1231-262 1231-260 1231-259 1231-283 1231-285 1231-273 1231-275 1231-279 9415 0008 000 1231-264 1231-263 1231-257 1231-256 1231-282 1231-284 1231-272 1231-274

1) 18.9 litre pail (5 US gallons)

06 technical data.fm

The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type A B C H Sabroe oil Mobil Gargoyle Arctic 300 - M1 (M68) Sabroe Oil PAO 68 - PAO 3 (PAO 68) Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220) Sabroe H oil - E 11 (E 370)

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6. Technical Data

ContactYORK Refrigeration

R22
one-stage reciprocating compressors
Condensing temperature

TC
F 122 104 86 68 50 32 C 50 40 30 20 10 0 A

14 -10 -4 -20

-22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50

20 C 68 F

TE

Evaporating temperature

Code no A3

Area no 1

a: c:

Very suitable in case of a new plant. Max oil concentration in liquid phase at TE: 2% W. Min suction temperature -50C. At TE<-50C superheating must be introduced.

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R22
two-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30 A

68 20 50 10 32 0

14 -10 -4 -20 -22 -30 -60 -76 -50 -58 -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

06 technical data.fm

C F

TE

C Evaporating temperature

Code no A3

Area no 1

a: c:

Very suitable in case of a new plant. Max oil concentration in liquid phase at TE: 2% W. Min suction temperature -50C. At TE<-50C superheating must be introduced.

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6. Technical Data

R134a
one-stage reciprocating compressors
Condensing temperature

TC
F C

158 70 140 60 122 50 104 40 86 68 50 32 30 20 10 0

14 -10 -4 -20 -22 -30 -60 -50 -40 -30 -20 -10 -76 -58 -40 -22 -4 14 0 32 10 50 20 68 30 C 86 F

TE

Evaporating temperature Code no 1 E5 E9 Area no 2

L:

Very suitable in case of a new plant. Zone in which both oils are applicable.:

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R134a
two-stage reciprocating compressors
Condensing temperature
F

TC
C 158 70 140 60 122 50 104 40 86 68 50 32 30 20 10 0

14 -10 -4 -20

06 technical data.fm

-22 -30 -40 -40 -70 -60 -50 -40 -30 -20 -10 -94 -76 -58 -40 -22 -4 30 C 86 F

10 50

20 68

TE

14 32

Evaporating temperature Code no Area no 1 E5

Very suitable in case of a new plant.

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6. Technical Data

R407C
one-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30 -60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

TE
F

Evaporating temperature

Code no

Area no 1

E3

: :

Very suitable in case of a new plant. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature -50C. At TE<-50C superheating must be introduced.

b: c:

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R407C
two-stage reciprocating compressors

TC
F C

122 50 104 40

Condensing temperature

86

30 B

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

06 technical data.fm

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

TE
F

Evaporating temperature

Code no

Area no 1

E3

: :

Very suitable in case of a new plant. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature -50C. At TE<-50C superheating must be introduced.

b: c:

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6. Technical Data

R404A
F

TC
C

one-stage reciprocating compressors


Condensing temperature

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

C F

TE

Evaporating temperature Code no 1 E3 E5 Area no 2

: :

Very suitable in case of a new plant. Min suction temperature -50C. At TE<-50C superheating must be introduced Zone in which both oils are applicable.

c: L:

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R404A
F

TC
C

two-stage reciprocating compressors


Condensing temperature

122 50 104 40 86 68 30 20

50 10 32 0

14 -10 -4 -20

06 technical data.fm

-22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

TE
F

Evaporating temperature

Code no

Area no 1

E3

: :

Very suitable in case of a new plant. Min suction temperature -50C. At TE<-50C superheating must be introduced.

c:

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R410A
HPO and HPC reciprocating compressors
Condensing temperature

TC
F 122 104 86 30 68 50 32 14 -20 -4 -30 20 10 0 -10 A 1 C 60 50 40

-22 -40 -60 -50 -40 -30 -20 -10 -76 -58 -40 -22 -4 0 10 50 20 68 30

40

50 F

14 32

Code no

Area no 1

Evaporating temperature

E5

: :

Very suitable in case of a new plant. Max oil concentration in liquid phase at: TE: 2%W

a:

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6. Technical Data

R507
one-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

06 technical data.fm

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

TE
F

Evaporating temperature

Code no

Area no 1

E5

: :

Very suitable in case of a new plant. Min suction temperature -50C. At TE<-50C superheating must be introduced.

c:

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R507
two-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

1
68 20 50 10 32 0

14 -10 -4 -20 -22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68

TE
F

Evaporating temperature

Code no

Area no 1

E5

: :

Very suitable in case of a new plant. Min suction temperature -50C. At TE<-50C superheating must be introduced.

c:

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6. Technical Data

List of Major Oil Companies


The oil from the companies listed below are not tested by YORK Refrigeration and are therefore not approved by YORK Refrigeration. The following list includes the information provided by the oil companies. The oil companies are responsible for the information concerning the durability and suitability of their oils for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part Numbers for Available Sabroe Oils".
Oil Company M A Oil Types PAO AP E

Aral Avia BP Castrol Chevron (UK: Gulf Oil) CPI Engineering Services DEA Elf / Lub Marine 1 Esso/Exxon Fina Fuchs Hydro-Texaco ICI Kuwait Petroleum (Q8) Mobil Petro-Canada Shell Statoil Sun Oil

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7. Installation Instructions

7. Installation Instructions
The purpose of this document is to describe: the dangers which may occur when the instructions and safety precautions pertaining to the installation phase are not followed, how to install the equipment in a safe and effective way.

Safety Precautions
Read Section 3, Safety Precautions, carefully before commencing the installation. If in doubt, please contact YORK Refrigeration. The safety precautions and instructions pertaining to the individual sections of this document must also be read and followed.

This document is intended primarily for the installation supervisors, installation technicians and electricians. It can also be used in sales activities to inform future customers of the requirements made in connection with the installation of a compressor unit. YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

Installation Data
The physical data of the compressor are included in Section 5, Physical and Connection Data. See also Section 6, Technical Data - Noise from compressors and units, Laying the foundation.

07 installation instructions.fm

Installation Drawings
Before commencing the installation, make sure that drawings showing how to connect the unit are available.

Personnel Requirements
The personnel which carry out the installation must be well-trained within the area of refrigeration technique, possess knowledge of refrigeration systems and have experience with pipe as well as wiring installations. Where authorisation is required, the electrician must possess an approved authorisation. The compressors must only be connected by an authorised refrigeration company.

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before starting the installation process. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

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7. Installation Instructions

Preparing the Installation


This section describes the preparations which must be carried out before commencing the installation.

Safety shoes Gloves Eye protectors Fire-fighting appliances Salt water solution for eye rinsing Oxygen equipment

Tools and Accessories


The list below shows the tools, accessories and materials which are necessary in order to carry out the installation correctly.

Local Regulations
The installation must be carried out in accordance with the prevailing rules of the installation site and the regulations of the area in question. When in doubt, contact the local authorities.

Ordinary Hand Tools


Tools for installing pipes, including welding tool Tools for wiring Special tools Small tool set for compressor. See Document no. 0662-061-EN. Accessories Lifting eye Shakles Hand-operated oil charging pump, spare part no. 3141-026, see description in Section 6, Technical Data - Charging the compressor with oil.

Space Requirements
Dimensions for all compressor types and units are included in the binder Dimensions and Piping Diagrams. Note in particular the minimum distances, which must ensure that the compressor can be serviced under all kinds of conditions, e.g. replacement of crank shaft or filter insert. The piping must be laid in such a way that the access to the top covers is not obstructed.

Preparing the Mounting Site Safety Equipment

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment. When installing the equipment, use the following safety equipment which must be in good condition:

Before installing the unit, the following must be carried out: 1. The foundation for the unit must be ready. Check that the foundation is level and has the necessary strength. Check that the access roads are wide enough for the unit to pass through - see the dimension sketches. Block the mounting site. The mounting site must be blocked to prevent unauthorised personnel from being injured or causing damage. The mounting site must be cleared.

2.

3.

4.

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7. Installation Instructions

Lifting Accessories and Equipment


See Section 14, Transport Instructions.

Cooling water hoses for cooling of top and side covers. Vibration dampers as well as drawing indicating the position of the dampers.

Preparing Lifts
See Section 14, Transport Instructions.

Lifting and Loading Instructions


See Section 14, Transport Instructions.

Disposal of Materials which are not Reusable


Materials from the packing of the unit which cannot be reused must be disposed of according to local regulations.

Unpacking and Inspection


On receipt the unit is wrapped in PE plastic film. After unpacking the unit, check for transport damage. Check also whether the delivered goods correspond to the specification. Check in particular that the control system and valves fitted on the outside of the unit are not damaged. It must also be checked whether the following parts are included: Intermediate piece for coupling, inner and outer screen and perhaps loose coupling hub for motor.

Moving the Equipment to the Mounting Site after Unloading and Unpacking
After unloading and unpacking the unit, it must only be lifted in the lifting eyes welded on the frame. If the unit is moved with e.g. a forklift truck, it must be placed on a pallet intended for the purpose. Secure the unit so that it does not tip over when starting, turning and braking the forklift truck. Do not lift directly under the unit.

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Installation Instructions

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment. To ensure the compressor and the motor a long life and a noise and vibration free operation, the compressor unit and coupling need to be aligned with care. Misalignment of the compressor unit or coupling may result in stresses and vibrations which can be transmitted to the compressor bearings, thus causing major damages. Vibrations may be caused by the following: Distortion between compressor unit and foundation. Distortion between compressor and base frame. Distortion between motor and base frame. Strains from pipe connections between compressor and plant. Incorrect alignment of coupling between compressor and motor. Compressor or motor shafts are untrue. Coupling is untrue. Imperfect balancing of coupling. Imbalance in compressor and motor.

The supervisor who sets up the unit is responsible for the points up to and including alignment of the coupling. The other points must be checked by the compressor and motor manufacturer before delivery. The following sections will deal with the individual points concerning the supervisor.

1. Alignment of Unit against Foundation


When the unit has been moved to the site where it is to be installed, an alignment must be carried out before the piping can be laid. When mounting the unit on the foundation or the machine floor, it must rest evenly on all its supporting surfaces. The unit can be mounted in the following ways: on vibration dampers. directly on the foundation with foundation bolts.

With both methods the unit must be set up before the pipes are connected to the plant. Depending on whether the unit is to be used on land or on a ship, vibration dampers are supplied as shown in the drawing Fig. 7.1. The purpose of the vibration dampers is to dampen the vibrations from the unit to the foundation. Moreover, the marine vibration dampers must dampen the vibrations from the foundation to the compressor unit and at the same time secure the unit to the foundation. It is very important that the vibration dampers are placed correctly as illustrated in the drawing forwarded to the customer or the dealer. This drawing applies only to the unit in question.

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7. Installation Instructions

Mounting on Vibration Dampers


Fig. 7.1

1
A1

A2
H

Hmax

07 installation instructions.fm

A1 A2

T0177040_0

The vibration dampers supplied are marked with a code, e.g. LM6-60. LM6 indicates the size whereas 60 indicates the rubber hardness and is thus an expression of bearing and damping capacity. When using vibration dampers, the foundation is assumed to have the necessary bearing strength and to be level enough to enable adjustment of the vibration dampers to be made within the adjusting measurements stated on the drawing submitted. In order for the individual vibration damper to dampen properly, a sufficient load must be imposed: Measure A1 and H (unloaded position) and A2 (loaded position) as shown in drawing Fig. 7.1.
Flexion A1A2 Height adjustment

Industrial type 1 min 1.0 max 2.0 Hmax= H+12

Marine type 2 min 3.0 max 5.0 with disks supplied as shown

The flexion of a damper is adjusted by increasing or decreasing the load in relation to the other supports. The foot can be raised by lowering the adjusting rod or inserting more disks between damper and foot (marine design), thereby increasing the load and hence also the flexion. Once the installation has cooled down, check during operation that the flexion of the dampers is still correct!

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7. Installation Instructions

Mounting Directly on Foundation


When mounting the unit directly on a concrete foundation, the foundation must be cast in accordance with the foundation drawing forwarded. When the foundation has been cast - with the holes shown for the foundation bolts - and has cured, place the unit in a position allowing it to rest on beams levelled at a suitable height so that the foundation plates are recessed slightly into the foundation. Check that the foundation plates are right next to the base frame. This can be achieved by binding them to the resting surfaces of the base frame by means of steel flex. The concrete which is cast down around the foundation bolts should only have minimal water content to allow it to be rammed well down around the bolts. Low water content does not cause the hardening concrete to shrink. 10-14 days should pass before removing the beams and tightening the nuts for the foundation bolts. Before that, however, remove the steel flex and check that there is no space between the base frame and the foundation plates. If there is, place shims between the plates before tightening.

2. Alignment of Compressor on Base Frame


Check that the entire footing of the compressor makes full contact against the faces of the base frame. Perform this check with the bolts loosened. If slip occurs at one or more resting surfaces, shim up before tightening. If unaligned, there is a risk of stresses occurring in the compressor frame, which will damage the bearings.

3. Alignment of Motor on Base Frame


Check the contact faces of the motor against the base frame in the same way as for the compressor.

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7. Installation Instructions

Fitting and alignment of coupling type AMR 4. Installation and alignment


In principle, alignment involves manoeuvring the motor to make the shaft form an extension of the crankshaft. Fig. 7.2 Important! Before performing any work on the coupling, make sure that the compressor motor cannot start inadvertently.

1 Z D a X 2

07 installation instructions.fm

A F C

Table 7.1
Distance mm Compressor Coupling size C Nominal* 102 113 F Torque Nm A B D

SMC 104-106-108 SMC 112-116 * See final installation

312 S 350 S

25 27

147 147

55 128

44 44

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7. Installation Instructions

Preliminary installation
Note: Never tighten the cone screws "D" unless there is a shaft inside the bore. Otherwise it might damage the cone system. Degrease the compressor shaft and hub bore surfaces. Any lubricant here will reduce the transferred torque. Place the hub at the compressor side, observing the measurement "F". Tighten the screws "D" crosswise in two or three steps of torque. Assembly is completed when no screw can be tightened any further (one by one) with tightening torque D. Place the hub at the motor side. Tighten the bolts "A" and the pointed screw loosely. Mount the retaining plate from the coupling screen onto the compressor and insert a support ring for the coupling screen over the motor flange. Assemble the intermediate piece and the lamella segments with the 8 screws, applying the prescribed torque. Remember the shaped washers facing the lamellas. Insert the coupling intermediate piece. Create space between the flanges either by shifting the entire motor or just the motor coupling flange. The intermediate piece should only be secured to the compressor flange. Do not insert the last four bolts in the motor flange until the coupling has been aligned. As the compressor shaft rotates during the alignment procedure, the motor must turn with it, as the bolts in the intermediate piece engage in the free holes in the motor coupling flange. Line up the motor so that the free holes in the motor feet are right above the threaded holes in the base frame. Shift the motor coupling flange to make up distance "C" in table. See Table 7.1. Tighten the two bolts and the pointed screw in the hub. Tighten the measuring pin on the coupling flange of the compressor, as shown in the drawing.

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7. Installation Instructions

Alignment
Check that the motor with loose bolts is positioned with all four feet on the base frame. Insert any liner plates needed where there is an air gap beneath the feet. Tighten the bolts loosely. Achieving parallel shafts in horizontal plane Turn the coupling so that the alignment gauge is in upper position. See Fig. 7.2. Guide the measuring pin (pos. 2) towards the coupling flange, using a 1.0 mm feeler gauge, and fix the pin. Remove the feeler gauge. Rotate the coupling 180 and measure the change in distance from the measuring pin to the flange, using feeler gauges. This change is called "x". Measure the distance b between the motor feet as shown in Fig. 7.3. Measure the distance a from the centre of the pin pos. 2 to the centre of the motor as illustrated in Fig. 7.2
y

Insert shims of thickness "y" either under both front feet or both rear feet, thereby tilting the motor in the direction required. Shim thickness "y" is calculated by using the following formula (see also Fig. 7.3):

y= X
Fig. 7.3

b 2xa

07 installation instructions.fm

After tightening the motor bolts, repeat the measurement and compare the result with the values in the table below:

Table 7.2
Maximum variation (mm) measured with feeler gauge at a 180 turning of the coupling Compressor Coupling size Horizontal max. mm SMC 104-106-108 SMC 112-116 312 S 350 S 0.2 0.2 Pos 1 Vertical min./max. mm 0.1/0.3 0.1/0.3 Pos 2 max. mm 0.2 0.2

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7. Installation Instructions

Achieving correct centre height


Turn the coupling so that the alignment gauge faces vertically down. Guide the measuring pin (pos. 1) towards the coupling flange, using a 1.0 mm feeler gauge, and fix the pin. Remove the feeler gauge. Rotate the coupling 180 and measure the increase in distance "z" from one millimetre using feeler gauges. Then lift the motor by placing shims of a thickness equal to half value of "z" under all four feet. After securing the motor, repeat the measurement and compare the result with the table values in pos. 1 vertical. Remember that the centreline of the motor shaft must be at least 0.05 mm higher than the centreline of the compressor, corresponding to a minimum of 0.1 mm distance less at the top position of the alignment gauge. Turn the coupling 180 and by using feeler gauges measure deviations from one millimetre at both pins. Move and turn the motor and repeat this measurement, align the motor in accordance with pos. 1 horizontal and pos. 2 in the table. Remember that the motor must be firmly secured during any measurements.

Final installation
Tighten the foundation bolts on the motor (see torque table). Fit four bolts into the motor coupling flange so that thin shims are placed between the flange and the lamellae, with the rounded side facing lamella. Tighten the bolts to torque specified in the table. Readjust the flange distance "C" so that the lamellae are aligned, by moving the motor flange on the shaft and fastening the motor flange. Check the alignment of the coupling in horizontal and vertical planes for pos. 1 and pos. 2. Dismantle the measuring pin and tighten the screw to the prescribed torque. Fit the coupling guard. Once normal operating temperature has been achieved, double-check the coupling alignment.

Achieving parallel shafts in vertical plane


The motor is now positioned at its correct height. What remains is to push and turn the motor at the level on which it is already lined up. Turn the coupling so that the alignment gauge faces out to one side horizontally. Guide both measuring pins towards the coupling with a 1.0 mm feeler gauge in between.

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7. Installation Instructions

Preliminary Installation
Check tightening of coupling flange on compressor. Tighten 8 coupling bolts securing lamellar segments to intermediate piece to prescribed moment stated in table. It is worthwhile doing this before placing the intermediate piece in position. Mount retaining plate from coupling screen onto compressor and insert support ring for coupling screen over motor flange. Insert coupling intermediate piece. Create space between flanges either by shifting entire motor or just motor coupling flange. The intermediate piece should only be secured to the compressor flange. Do not insert the last four bolts in the motor flange until the coupling has been aligned. As the compressor shaft rotates during the alignment procedure, the motor must turn with it, as the bolts in the intermediate piece engage in the free holes in the motor coupling flange. Line up motor so that free holes in motor feet are right over threaded holes in base frame. Shift motor coupling flange to achieve distance "C" in table, Fig. 7.2. Tighten two bolts in coupling hub. On CMO-HPO units, the motor flange must be correctly positioned before putting the motor into place. Tighten alignment gauge on coupling flange of compressor as shown in drawing.

Alignment
Check that the motor with loose bolts stands with all four feet on the base frame. If necessary, insert any liner plates where there is an air gap beneath the feet. Tighten the bolts slightly.

Achieving Parallel Shafts in Horizontal Plane


Turn coupling so that alignment gauge is in upper position, Fig. 7.2 Guide measuring pin (Pos. 2) towards coupling flange by means of a 1.0 mm feeler gauge and fix pin. Remove feeler gauge. Rotate coupling 180 and measure change in distance from measuring pin to flange by means of feeler gauges. This change is called "x". Measure the distance b between the feet of the motor as shown in Fig. 7.4. Measure the distance a from the centre of the pin pos. 2 to the centre line of the motor as illustrated in Fig. 7.2 Insert shims of thickness "y" either under both front feet or both rear feet, thereby tilting motor in direction required. Shim thickness "y" is calculated using the following formula (see Fig. 7.4):

07 installation instructions.fm

y = X

b 2xa

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Fig. 7.4

Turn coupling so that alignment gauge faces out to one side horizontally. Guide both measuring pins towards coupling with a 1.0 mm feeler gauge in between. Turn coupling 180 and measure deviations from one millimetre at both pins by means of feeler gauges. By moving and turning motor and by repeating this measurement, align motor in accordance with pos. 1 horizontal and pos. 2, Fig. 7.2. Remember that the motor must be firmly secured when measuring.

After tightening motor bolts, repeat measurement and compare result with values in table under Pos. 2, Fig. 7.2

Achieving Correct Centre Height


Turn coupling so that alignment gauge faces vertically downwards. Guide measuring pin (pos. 1) towards coupling flange by means of a 1.0 mm feeler gauge and fix pin. Remove feeler gauge. Rotate coupling 180 and measure increase in distance "z" from one millimetre by means of feeler gauges. Then lift motor by placing shims of thickness equal to half value of "z" under all four feet. After securing motor, repeat measurement and compare result with table values in pos. 1 vertical, Fig. 7.2 Remember that the centre line of the motor shaft must be at least 0.05 mm higher than the centre line of the compressor, corresponding to a minimum of 0.1 mm distance less at the top position of the alignment gauge. 2.

Final Installation
Tighten foundation bolts on motor (see table showing the torque for screws and bolts). Fit four bolts into motor coupling flange so that thin shims are placed between flange and lamellae with rounded side facing lamella. There are no thin shims on couplings for CMO and HPO. Tighten bolts to torque specified in table. Readjust flange distance "C" so that lamellae are aligned by moving motor flange on shaft and securing motor flange. Check alignment of coupling in horizontal and vertical planes for pos. 1 and pos. 2, Fig. 7.2 Dismantle alignment gauge and tighten screw to prescribed torque. Fit coupling guard. Once normal operating temperature has been achieved, double-check coupling alignment.

1.

Achieving Parallel Shafts in Vertical Plane


The motor is now positioned at its correct height. What now remains is to push and turn the motor at the level on which it is already lined up.

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5. Piping Connections
In order to prevent stress from being transmitted from piping connections between unit and plant, pipes must be laid so as not to generate compressive stresses or tensile strains in the event of expansions or contractions due to temperature changes. Steel pipes expand approx. 1 mm per metre per 100C. We recommend that piping be laid as shown in example 2 of the sketch, Fig. 7.5. Example 1 demonstrates too rigid pipe laying. Fig. 7.5
> 1.5 m

5.1 Refrigerant Connection to Compressor The connecting pipe is to be welded onto a connecting branch on a stop valve. In order to protect the stop valve when welding, remove the insides of the valve. Do not put the insides back into the valve until the weld has cooled off - see the instructions from the valve manufacturer in Section 21, Appendices. The welding must be carried out according to the specifications and standards applying to the plant in question. 5.2 Refrigerant Connection to Oil Cooler (OOKH og OSSI)

07 installation instructions.fm

The connection to the oil cooler is indicated on the compressor with V for water supply and Q for return. See section 5, Physical and Connection Data.
T0177057_0

Final alignment of compressor and motor can be performed once all piping has been connected to the unit. Section 5, Physical and Connection Data includes data concerning dimensions and descriptions of piping connections. The piping connections which must be made are outlined below:

5.3 Connection to Water-Cooled Top and Side Covers The water cooling hoses are delivered separately and connected to top and side covers according to enclosed mounting instructions. Connect water supply to the inlet of the water system and establish return to drain or the like, e.g. cooling tower for reuse of the water. Connection dimensions are included in Section 5, Physical and Connection Data. The system is described in detail in Section 4, Technical Description.

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6. Connecting Electricity Supply


Data for the electrical components of the unit and their supply is included in Section 5, Physical and Connection Data. Remember! Check that the direction of rotation is correct - see Section 6, Technical Data Direction of Rotation of Electric motor. 6.2 Connecting UNISAB Two manuals are delivered together with UNISAB II: - Starting-up Manual which is placed inside the UNISAB II cabinet on delivery. - Instruction Manual delivered together with other documentation. Installation UNISAB II is placed on a bracket on the unit, see dimension sketches in Dimensions and Piping Diagrams. To gain access to the terminals, open the cabinet by loosening the screws which hold the operating panel. Lift up the panel as shown in Fig. 7.6 and take out the Starting-up Manual. The Starting-up Manual includes key diagrams for UNISAB II. These are included under the section Supplementary Instructions. In this Installation Manual references are made to these key diagrams. Fig. 7.6 Opening the Cabinet

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment. Before connecting, make sure that there is no power on the cables which are to be connected, the power cannot be connected accidentally. This can be done by locking the switches or placing a sign indicating that the connection in question must not be connected. After being connected, all electrical connections should be checked by an electrician. 6.1 Connecting the Motor Installation and connection instructions for the chosen motor type is order specific and delivered together with the unit by YORK Refrigeration. These data sheets include descriptions of how to connect the motor. Where another motor type is used, data sheets containing this information must be obtained. Motor data appear from the name plate on the motor. Important! Always follow the instructions from the manufacturer concerning connection.

Connecting Supply Voltage The supply voltage 230 VAC, 115 VAC is led through the screwed cable entry and connected to

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the terminals marked L (phase) and N (zero) - see page 010 in diagram 2347-003. Check that the jumper for 220/115 VAC corresponds to the supply voltage used. As standard UNISAB II is prepared to be supplied by 230/115 VAC, but UNISAB II can also be supplied by 24 VAC. If this is the case, another transformer must be used. Check that the correct transformer 24/24 VAC (YORK Refrigeration product no. 1556.043) has been fitted. Check, moreover, that the jumper for 220/115 VAC has been removed and that components, e.g. solenoid valves, are designed for 24 VAC. Connections to Motor The control supply of the motor must be connected across terminals 118 and 119 on UNISAB II to which the control system gives start signal to the compressor - see page 021 in the diagram 2347-003. Connect a potential free digital feedback signal from the motor starter to terminals 41 and 42. This signal informs the control system that the motor is operating. See page 014 in diagram 2347-003. It is possible to connect a signal to terminals 35 and 36 from the motor starter via a current trans-

former XXX/1 A AC, which reads the motor current taken up. Terminals 35 and 36 must be supplied with max. 1A - see page 013 in diagram 2347-003. Other Connections UNISAB II's alarm output is made in such a way that under normal conditions there is a connection between terminals 107 and 109 whereas in an alarm situation there is a connection between terminals 107 and 108. The alarm output is supplied by applying max. 230 V to terminal 107 - see page 020 in diagram 2347-003. UNISAB II is prepared for connection of thermopump. The connection is shown on page 028 in diagram 2347-003. 6.3 Control without UNISAB II Where the unit is to be controlled by a control system which is not delivered by YORK Refrigeration, the connection must be made as described in the key diagrams pertaining to the control system in question. Section 21, Appendices includes data sheets for the individual control components with more detailed descriptions of how to carry out the connection.

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7. Installation Instructions

7. Pressure Testing
After installing the unit, it must be pressure tested and pumped down. 7.1 Pressure Testing of the Refrigeration Plant Before charging the plant with refrigerant, it must be pressure tested and pumped down. Pressure test the plant with one of the following: dry air - pressurized cylinders containing dry atmospheric air may be used but never oxygen cylinders; air compressor for high pressure; Important! The plant compressors must not be used to pressurize the plant. Water and other fluids must not be used for pressure testing. If nitrogen is used, it is important to place a reducing valve with a pressure gauge between the nitrogen cylinder and the plant. During pressure testing, it is important to ensure that pressure transducers and other control equipment are not exposed to the testing pressure. The compressor stop valves must also be closed during pressure testing. Plant safety valves must normally be blanked off during pressure testing, as their opening pressure is lower than the testing pressure. Shut-off valve pos. 4K-1 must be closed during pressure testing. Important! During this pressure testing no person should be allowed to be present in rooms housing plant parts or in the vicinity of the plant outside the rooms.

The entire plant must be pressure tested in accordance with the local regulations for pressure testing. The test pressure must never exceed the pressure for which the unit was designed. If it is required that the compressor should be pressure tested together with the unit or with the plant, the testing pressure must not exceed:

For reciprocating compressors: - HT side 24 bar - LT side 17.5 bar Please observe that manometers, pressure controls, pressure transmitters and other control equipment are not exposed to testing pressure. Afterwards, reduce pressure to 10 bar for a period of 24 hours - as an initial tightness test - as a tightly sealed plant will maintain this pressure throughout the period.

During the tightness test, it is permitted to enter the room and approach the plant. By way of a second tightness test, examine all welds, flange joints etc. for leakage by applying soapy water while maintaining the pressure of 10 bar.

When pressure testing, prepare a pressure test report containing the following points: date of pressure testing, person carrying out the test, comments.

7.2 Pumping Down the Refrigeration Plant Following pressure testing, the refrigeration plant must be evacuated in order to eliminate atmospheric air and moisture. Evacua-

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tion must be carried out on all types of plants, regardless of the type of refrigerant with which the plant is to be charged. Note that HCFC and HFC refrigerants mix only minimally with water and it is, therefore, necessary to effect evacuation of such systems with particular care. The boiling point of a fluid is defined as the temperature at which the steam pressure equals atmospheric pressure. For water the boiling point is 100C. If the pressure is lowered, the boiling point of the water will also be lowered. The table sets out the boiling point of water at very low pressures: 07 installation instructions.fm Table 7.3
Boiling point of water C 5 10 15 20 At pressure mm HG bar 6.63 9.14 12.73 17.80 0.0088

Important! Never use the refrigeration compressor to evacuate the plant. For an evacuation to be performed satisfactorily, the final pressure must be lower than 5 mm Hg. Please note that water left in the refrigeration plant may freeze if ambient temperatures are lower than 10C. In such cases it will be necessary to supply heat to the component surroundings, as ice evaporates with difficulty. It is recommended to carry out evacuation as follows: Evacuate to a pressure lower than 5 mm Hg. Blow dry air or nitrogen into the system to a pressure corresponding to atmospheric pressure. Never use OXYGEN cylinders. Repeat evacuation to reduce pressure to less than 5 mm Hg. Shut off the vacuum pump from the refrigeration plant and check that the pressure does not rise for the next couple of hours. If the system still contains water, this will evaporate and cause the pressure to rise, thereby indicating unsatisfactory evacuation, which means that the above procedure must be repeated.

0.0122 0.0170 0.0237

For evacuation, use a vacuum pump which empties the plant of air and steam. The vacuum pump must be able to lower the pressure to approx. 0.1 mm Hg (mercury column) and must be fitted with a gas ballast valve. This valve should be used wherever possible to prevent water vapour condensing in the vacuum pump.

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8. Oil Charging
Since the compressor is usually delivered without any oil in the crank case, oil must be charged in

accordance with the oil recommendation before start-up.

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Final Check of the Installation


After the installation has been completed, go through the following check list.

WWarning!
It is of vital importance that all security systems and their functions are checked before start-up. Failure to comply with safety precautions may cause death, personal injury or damage to the equipment.

Table 7.4
Check list for the installation 1 2 3 4 5 Level foundation Position of vibration dampers Position of motor on foundation Position of compressor on foundation Tightness of pipe connection Measure whether the foundation is level Measure flexion Check that the motor rests on all four supporting surfaces Check that the compressor rests on all four supporting surfaces Pressure testing: After putting the unit under pressure, paint with soapy water around welds, thread connections and union nuts. Check that the alignment is in order - must be checked again after 5 hours of operation while the coupling is warm. Check that all bolts are tightened to the torque indicated. Check all electrical connections e.g. by measuring. Check that the oil in the crankcase goes up to the middle of the sight glass. OK

07 installation instructions.fm

Coupling between motor and compressor

7 8 9

Torque Electrical connection Oil charging

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8. Components

8. Components
The purpose of this document is to describe the components which form part of the product as well as the variety of accessories which can be mounted. This document is primarily intended for constructing engineers, service technicians, future customers, sales personnel and personnel in the process of training. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration 08 components.fm This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted. Variable speed drive (VSD) in connection with computerized capacity regulating system.

Valves
Suction valve Discharge valve Oil charging valve Purge valve Thermostatic expansion valve for intermediate cooling (TSMC) Thermostatic expansion valve for oil cooling Solenoid valves for oil cooling and intermediate cooling Solenoid valve block for capacity regulation

Equipment General
SMC 100 and TSMC 100 compressor blocks and units are available in different versions with different components. Oil separator Oil cooler Float valve for oil return Intermediate cooler (TSMC) Heat exchanger for intermediate cooling (TSMC) Heating element

Regulating Systems
Electromechanical control (analogue reading and safety system). Computerized reading, safety and capacity regulating system.

For further information regarding dimensions and location, please see the binder Dimensions and Piping Diagrams as well as Section 5, Physical and Connection Data.

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8. Components

Motors
The standard SMC 100 and TSMC 100 units are available with motors in different sizes, with different enclosures, power and supply voltage. Makes: Schorch and Leroy-Somer Supply voltage: 3x380V 50 Hz or 3x440V 60 Hz Enclosure class: IP 22/23 or IP 54/55 Size: IEC 160 - 355

a belt pulley diameter of 400 mm. The required transmission of speed between motor and compressor is achieved by choosing the right standard belt pulley for the motor. See, moreover, Section 6, Technical Data where both systems are described in detail.

Oil Separators
Section 6, Technical Data - Oil separators includes a complete list of application areas for the individual oil separators. The function and mode of operation of the oil separator are described in detail in Section 4, Technical Description.

The necessary motor power depends on the operating conditions of the unit. The motor size can be determined on the basis of the calculations in the calculation program COMP1.

Transmission Systems
SMC 104-106-108 and TSMC 108 are available either directly driven or belt driven.

Oil Coolers
See Section 4, Technical Description - Cooling Systems for Compressors where the oil cooling principles are described in detail. The table below shows which oil cooler (depending on the type of refrigerant) forms part of the units. Table 8.1 Refrigerant-Cooled Oil Cooler
Refrigerant R 717 HFC/HCFC

Directly Driven
The power transmission between motor and compressor takes place by means of a coupling. Type of coupling AMR 312 is used for SMC 104-106-108 and TSMC 108 and type AMR 350 for SMC 112-116 as well as TSMC 116. A coupling hub with bushing is mounted on the compressor. A hub adjusted to the chosen motor size is mounted on the motor. Moreover, the coupling consists of an outer and inner screen and a coupling intermediate piece. These parts are not mounted when the compressor is delivered. They are, however, included in the delivery. In cases where the unit is delivered without motor, coupling hub for motor is also included.

Oil Cooler Model OSSI OOKH

Table 8.2
Combinations Water-cooled top and side covers Air-cooled top covers and water-cooled side covers Air-cooled top and side covers, refrigerant-cooled oil cooler Thermo pump Chosen on the basis of operating limits

Belt Driven
The power transmission takes place by means of V-belts. The compressor is always delivered with

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8. Components

Regulating Components Electromechanical Control


The following components form part of the electromechanical control: KP15 KP5 MP55 KP98 KP98 KZD4/M3 High and low pressure cut-out Intermediate cut-out Oil difference cut-out Discharge pipe thermostat Oil thermostat Oil filter differential pressostat Moreover, the compressor is equipped with manometers for visual control of the pressure conditions. High pressure manometer: Indicating discharge pressure. High and intermediate pressure: Indicating discharge pressure for HP and LP Stages (TSMC). Low pressure and oil pressure: Indicating suction pressure and oil pressure.

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8. Components

UNISAB II
The UNISAB II control receives its impulses from pressure transducers and temperature sensors.

Pressure Transducers, marked PT1, PT2, PT3


For plants with UNISAB II control the unit is delivered with pressure transducers from Danfoss of the type: PT1: AKS32R and PT2 and PT3: AKS2050 see data sheet in Section 21, Appendices. For plants with another control the unit is delivered with pressure transducers from Danfoss of the type: PT1: AKS3000 and PT2 and PT3: AKS3050 see data sheet in Section 21, Appendices.

This type has a replaceable sensor insert placed in a protective pocket made of stainless steel, which makes it possible to replace the insert while the unit is under pressure, see data sheet in Section 21, Appendices. The regulating systems are described more closely in Section 4, Technical Description - Instrumentation.

Heating Element
The compressor is equipped with a heating element in the crankcase for decocting of refrigerant in the oil. See Section 4, Technical Data One-Stage Compressors and Section 5, Physical and Connection Data which include descriptions and data.

Accessories
If the compressor is to be installed in rooms where explosive gases may occur, special explosion-proof components can be delivered, see Section 4, Technical Description - Compressor Accessories.

Temperature Sensors, marked TT5, TT6 and TT7


As standard the unit is delivered with Pt100 temperature sensors of the type: P2208 G"B L80.

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9. Settings

9. Settings
The purpose of this document is to provide information about the factory settings of the safety and control equipment, how to change the settings and the effect of a change. This document is primarily intended for installation and service engineers. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without a written permission from YORK Refrigeration and the contents hereof must not be imparted to a third party, nor be used for any unauthorised purpose. Contravention will be prosecuted.

Safety Precautions

WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this document, always read the safety precautions belonging to this equipment before changing the settings. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

Qualification Requirements
Changes in the factory settings must only be carried out by an authorised refrigeration company. Moreover, it is required that the personnel is able to follow a detailed description in English. Factory settings for analogous control and safety system appear from Table 9.1. In connection with fault-finding in case of irregularities in the operation, the table should include own settings to make it easier for the supervisor to identify the error in question. The same applies to UNISAB II control. Table 9.2 and Table 9.3 show the set values for UNISAB II.

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Table 9.1

Pressure and Temperature Settings for Compressor Type SMC/TSMC


Refrigerant R 404A R 134 R 507 R 717 R22 Min. setting (own setting) 24 bar (standard) 22 bar (special) 12 bar Set so that the compressor stops at a pressure 2 bar lower than the safety valve set- ting. Set to a pressure with saturation temp. 5 K lower than the lowest evaporating temperature. 3.5 bar * 120 C X X X X X X X X X X X * 150 C 80 C 55 C Max. setting (own setting)

Analogous control and safety system

Safety valve on compressor SafetyEquipment

HT MT

X X X X

X X X X

X X X X

X X X X

X X X X

High and intermediate-pressure cut-out

KP5 (KP15) KP1 (KP15) MP55 KP98 KP98 KP77 T (E) X T (E) N T (E) S TEAT

Low-pressure cut-out Oil pressure cut-out Discharge pipe thermostat Oil thermostat Thermostat for compressor cooling Thermo valve for compressor cooling

X X X

X X X

X X X

X X

X X

X X

X X

X X X

ControlEquipment

Normally set at 4 C su- perheat Change to min. 10 C superheat Factory setting 45 C. See NB Factory setting 75 C. See NB Set at min.10 C superheat X Set at min.10 C superheat -25 C X -15 C 2,0 bar 4.5 bar

Injection valve for intermediate cooling

X X

T (E) X TEA PMC+ CVC KZD4/M3

By-pass valve Oil filter differential pressure Oil pressure regulating valve

X X

X X

X X

X X

X X

Factory setting - can be adjusted, if required, to a breaking point 20 C higher than the highest normal discharge pipe temperature.

** Adjust the TEAT valves so that the expected discharge pipe temperature (-5 C/+10 C) is achieved at 100% compressor capacity. Increase the opening temperature 10 C by turning the spindle 5 turns clockwise. NB: Factory setting must always be increased by min. 10 C. Adjustment of the TEAT valve must be carried out with the thermopump out of operation. For detailed descriptions concerning setting and adjustment of automatics, see Section 21, Appendices.

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UNISAB II Reading, Safety and Capacity Regulating System


Table 9.2
Mesuaring Suction pressure [bar] High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm

Measured and Calculated Pressure Levels


Min. 1,5 -1,0 -1,0 4,0 3,0 -1.0 4,0 3,0 -1,0 -1,0 5,0 5,0 0,5 0,5 Max. 9,0 6,0 6,0 24,0 22,0 -1.0 24,0 22,0 10,0 10,0 7,0 7,0 5,0 5,0 Factory Setting 5,0 2,5 1,5 16,0 15,0 -1.0 7,0 6,0 -1,0 -1,0 6,0 5,5 4,0 3,5 Note

3+4+5 3+4+5 3+4+5 1+6 1+6 1+5 1+6 1+6 1+6+16 1+6+16 2+5+16 2+5 2+5+14 2+5+14

Discharge pressure [bar]

Intermediate pressure [bar] For two-stage compressors only Oil pressure [bar] Calculated value

09 settings.fm

Table 9.3
Measuring

Measured and Calculated temp. - Reciprocating Compressors


Min. High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning 60,0 50,0 -65,0 40,0 30,0 0,0 0,0 -60,0 -60,0 -100,0 -100,0 50,0 50,0 -20,0 -20,0 6,0 5,0 0,0 0,0 5,0 0,0 Max. 155,0 155,0 -65,0 105,0 105,0 50,0 40,0 100,0 100,0 100,0 100,0 155,0 120,0 50,0 50,0 120,0 120,0 40,0 40,0 40,0 40,0 Factory Setting 125,0 120,0 -65,0 80,0 75,0 30,0 25,0 60,0 50,0 4,0 2,0 100,0 95,0 4,0 2,0 110,0 100,0 4,0 2,0 10,0 0,0 1+6 1+6 Note

Discharge temperature [C]

Oil temperature [C]

2 2 2+7 2+7 1+6 1+6 1+6 1+6 2+7 2+7 2+7 2+7 2+7 2+7 2+7+13 2+7+13 2+7+10 2+7+10

Brine temperature [C]

Intermediate gas temperature [C] For two-stage compressors only Suction gas superheat [C] Calculated value Disch. gas superheat [C] Calculated value

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9. Settings

4-20 mA Auxiliary input Signal


Measuring High alarm Auxiliary input (4-20 mA) High warning Low warning Low alarm Min. -999,9 -999,9 -999,9 -999,9 Max. 999,9 999,9 999,9 999,9 Factory 0,0 0,0 0,0 0,0 Note 3+18 3+18 3+18 3+18

Notes:
Note 1 Note 2 Note 3 Note 4 Note 5 The alarm cannot be switched off until the problem has been solved. The alarm can be switched off immediately (RESET key). The alarm is switched off automatically. The safety limits can be entered in bar or C/R at your choice. Alarm monitoring active when digital output "compressor starting signal" has been chosen. Alarm monitoring always active - except when "BLOCKED" has been selected in the picture COMPRESSOR CTRL MODE. Alarm monitoring 300 sec delayed after compressor start. Alarm monitoring 180 sec delayed after compressor start. Alarm monitoring 45 sec delayed after compressor start. A setting of 0.0 impedes monitoring. Delay of 300 sec, regardless of when the limits are exceeded. The compressor must have been above 5% capacity. Below 5% capacity monitoring is impeded. Note 19 Note 18 Note 13 Note 14 Note 15 Note 16 Note 17 Alarm monitoring 15 sec delayed after compressor start. Delay of 60 sec, regardless of when the limits are exceeded. Only applies to HPO and HPC compressors. Alarm monitoring 20 sec delayed after compressor start. For VMY Mk 2-2.5, calculate the following below: Oil pressure = Oil pressure 3 (after oil filter) - Discharge pressure 2. For all other compressor types (except for SAB 80, see Note 20), calculate the following: Oil pressure = Oil pressure 3 (after oil filter) - Suction pressure 1 . The limits are not active until AUX. INPUT SIGNAL has been selected in the CALIBRATION 4-20 mA menu. For SAB 80 the differential pressure across the oil filter is calculated as follows below: Oil filter diff. pressure = Discharge pressure 2 - Oil pressure 4 (after oil filter). The shown oil filter pressure will thus be 0.1 to 0.7 bar higher than the actual pressure loss across the filter due to the pressure loss across the oil separator and the oil cooler.

Note 6

Note 7 Note 8 Note 9 Note 10 Note 11 Note 12

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The maximum allowed pressure drop across the oil filter is 1.2 bar. Consequently, the warning limit should be set between 0.8 and 1.4 bar or lower. The alarm limit should be set between 1.1 and 1.7 bar or lower. Note 20: Set points 1 and 2 are used for alarm monitoring of the mechanical oil pump. Cf. the description of the alarm under "Oil pump error" in the section Other Alarms. For SAB 80, the oil pressure is calculated as follows below: Oil pressure = Oil pres-

sure 3 (after pump) - Suction pressure 1 . Note 21: The set points are used to control the oil pump. When the pressure falls below set point 1, the oil pump will start. When the pressure exceeds set point 2 for 60 seconds, the oil pump will stop. The set points are used to control the full flow pump. When the pressure falls below set point 1, the full flow pump will start. When the pressure exceeds set point 2 for 60 seconds, the full flow pump will stop.

Note 22:

Table 9.4
No.

Oil Cooling
Regulator Type Set point 1/ oil temp. Difference Oil cooling Set point 2/ oil temp. Difference Oil heating Set point 1/ discharge pipe temp. Difference Water cooling Set point 2/ discharge pipe temp. Difference Intermediate pressure liquid injection Min. +35 Max. +75 Factory Setting +55 5(fixed) +35 5(fixed) +100 5(fixed) +100 5(fixed) Unit

09 settings.fm

+75

-20

+150

-20

+150

Change af factory settings, see Instruction Manual, UNISAB II Control.

Fig. 9.1 - Expected Discharge Gas Temperatures - shows the values recommended when setting operational and safety functions.

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Fig. 9.1

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HFC HCFC

9. Settings

R134a
Evaporating temperature or intermediate temperature Evaporating temperature or intermediate temperature

R22
C C
0 42 7.6 9.1 77 65 83 102 121 142 95 113 133 151 53 71 91 110 131 47 52 57 62 67 52 7.6 9.1 57 62 67 72 77 62 67 72 76 82 87 81 66 71 76 81 86 91 76 82 87 73 78 83 87 92 71 77 66 73 61 68 77 56 63 72 65 77 71 77 66 72 61 67 75 12.6 56 63 71 10.7 51 58 67 46 53 62 10 20 30 40 +10 0 10 20 30
Evaporating temperature or intermediate temperature

R404A/R507
C

R717

Evaporating temperature or intermediate temperature

Condensing pressure bar

Condensing pressure bar

Condensing pressure bar

Condensing pressure bar

C
30 55 59 66 11.1 55 11. 74 12.7 68 79 14.5 72 14 82 16.5 81 65 69 76 11.1 65 11 84 12.7 73 12 89 14.5 82 14 92 16.5 90 16 75 79 86 11.1 75 11 94 12.7 84 12 86 98 111 125 14.3 69 9.5 69 9 78 91 105 120 12.5 64 8.2 59 8 70 83 97 113 11.0 60 98 109 121 133 20.5 75 92 103 115 128 18.2 69 84 96 109 123 16.2 64 76 88 102 117 14.3 59 9.5 57 9 68 80 95 110 12.5 54 8.2 48 8 59 72 88 103 11.0 50 90 100 112 126 20.5 65 82 94 106 120 18.2 59 74 85 99 115 16.2 54 65 77 92 108 14.3 49 9.5 47 9 57 69 84 101 12.5 44 8.2 37 8 48 61 76 91 11.0 40 +10 0 10 20 30

SMC /TSMC 100 Mk4 - Engineering Manual

Suction gas superheat C 89 106 123 141 160 79 14.6 101 117 133 151 170 83 16.9 110 126 143 161 83 103 122 143 95 114 132 153 89 106 125 142 162 89 14.6 111 127 144 162 93 16.9 121 136 154 171 82 87 7.6 9.1 78 96 115 134 153 90 106 126 144 163 91 10.7 102 118 136 154 95 12.6 112 128 146 163 99 14.6 123 138 155 97 103 16.9 132 148 165
Discharge gas temp. C

Condensing temp. C

+10

10

20

20 5.7

38

41

43

48

25 6.6

44

45

48

52

30 7.7

49

50

53

58

10

35 8.8

53

54

58

64

40 10.1 57

59

63

69

Expected Discharge GasTemperatures

45 11.5 61

63

67

74

20 5.7

48

51

53

58

25 6.6

54

55

58

62

20

30 7.7

59

60

63

68

81 10.7

35 8.8

63

64

68

74

85 12.6 100 116 134 152

40 10.1 67

69

73

79

45 11.5 71

73

77

84

20 5.7

58

61

63

68

25 6.6

64

65

68

72

30 7.7

69

70

73

78

Discharge gas temp. C

30

35 8.8

73

74

78

84

95 106 118 131 16.2 74

40 10.1 77

79

83

89

99 14.5 92 101 111 123 135 18.2 79 14

45 11.5 81

83

87

94 102 16.5 99 108 117 128 139 20.5 85 16

0178-931 - ENG

Discharge gas temp. C

Discharge gas temp. C

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SMC /TSMC 100 Mk4 - Engineering Manual

10. Operating Instructions

10. Operating Instructions


The purpose of this document is to describe: Dangers resulting from failure to comply with safety precautions when operating the equipment. How to start, operate and stop this equipment in a safe way. How to act when problems occur during operation.

Safety Precautions

WDanger!
A number of safety considerations which must be read before operating the unit in question are presented in the following. General safety instructions/regulations must be studied carefully. Failure to do so may result in personal injury or even death. Moreover, the equipment may be damaged or destroyed.

This document is primarily intended for operators and service engineers. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

Ventilation
Before operating the unit, always check to see that the ventilation system used in the area where the compressor unit is located (machine room) is functional and operating at full capacity. The safety instructions explain the risks associated with using the refrigerant and oil. Pay close attention to the fact that large amounts of escaping (or released) refrigerant entail risk of suffocation. The safety instructions also explain the risks generally associated with refrigerants. Body contact with leaking liquid refrigerant entails high risk for injuries caused by intense cold.

10 operating instructions.fm

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

Pressure
A compressor unit comprises a pressurized system. Never loosen threaded joints (such as a union nut) while the system is under pressure and never open pressurized parts of the system.

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10. Operating Instructions

Hot and Cold Surfaces


A compressor unit contains both hot and cold system parts. Always wear and use the re-commended safety items. Never use your hands or other parts of the body to search for leaks.

Qualification Requirements
Before carrying out the measures set forth in this document, all personnel must have carefully studied the instructions issued for the compressor unit. The personnel must also fulfil all national requirements for authorization.

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10. Operating Instructions

Compressor Control and Alarm Functions


The reciprocating compressors can be equipped with either analogue reading and regulating system or UNISAB II reading, safety and regulating system.

KP 98: Oil thermostat Stops the compressor at too high oil temperature.

Alarms and Warnings


Analogue System The system is described in detail in Section 4, Technical Description - Instrumentation, which is why this section only contains a short description of the system. Analogue reading and regulating system always require an external control board for the regulation of the capacity. The board can be equipped with alarms. The safety system consists of the following components: KP 15: High and low pressure cut-out Stops the compressor at too high or too low pressure in the refrigeration system. KP 5: Intermediate pressure cut-out (only on TSMC compressors) Stops the compressor at too high intermediate pressure. MP 55: Oil differential cut-out Stops the compressor at too low oil pressure in the lubricating system. KZD4/M3 Oil differential cut out Oil differential pressure across oil filter. A warning is given if the pressure drop through the external oil filter is too high. KP 98: Discharge pipe thermostat Stops the compressor at too high discharge gas temperature.

The safety equipment stops the compressor if the max. or min. values are exceeded. If this happens, correct the error before restarting the plant. To prevent accidents the plant cannot be started before the function of the safety cut-out has been activated. Cut-outs and thermostats are not factory set on delivery. The set values are included in Section 9, Settings - Analoque Control and Safety Function. However, always check the set values before starting the plant. As regards adjustment and setting of the equipment, see Section 21, Appendices, which includes instructions for the individual components.

10 operating instructions.fm

UNISAB II Reading, Safety and Capacity Regulating System


UNISAB II is a Computerized Control System, the purpose of which is to monitor and control the compressor. The signals to the control and safety automatics come from the pressure transmitters and temperature sensors mounted on the compressor. It is possible to connect UNISAB II to a superior monitoring device- MULTISAB. On delivery UNISAB II is preset with a number of factory values, e.g. safety and alarm functions. A battery backup makes sure that preset values are not lost in case of power failure. All control operations for the reciprocating compressor unit are carried out from the operator's panel and its keys. The following page in this document gives a brief explanation of what the keys on the operator's panel are used for.

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10. Operating Instructions

A detailed description of the control system, its functions and its use is included in the Instruction Manual for UNISAB II Control. The following are for normal daily operation of the reciprocating compressor unit. 1. The emergency stop button on the side of the control cabinet can always be used to stop the compressor unit quickly. When voltage is applied to UNISAB II, the following main picture will appear on the display, and UNISAB II is ready for operation.
SUCT. PRESS. DISCH. PRESS. MOTOR CURR. STOPPED 0.0 BAR 0.0 BAR 0A 0%

Carefully read the Instruction Manual UNISAB II Control to get a thorough knowledge of how to operate the control system. UNISAB II is operated exclusively by means of the keys as shown in Fig. 10.2. Reading of operating conditions as well as changing limit values and set points is done via the display, which contains a number of pictures. The control panel is normally closed and locked with a screw at each end of the panel. By turning the screws half a turn the control panel is loosened and can be lifted to an open position. Here it is fastened to the cabinet as shown in Fig. 10.1. Fig. 10.1 Opening the Cabinet

2.

UNISAB II

Values for warning limits, alarm limits and set points, etc. are programmed into UNISAB II. This makes it possible to start the compressor immediately. However, some of the values must always be adapted for the actual operating situation. For this purpose use the table Quick Reference, see Fig. 10.6, Fig. 10.7, Fig. 10.8 and Fig. 10.9.

UNISAB II

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10. Operating Instructions

Display
Pos. 1 Has a constant background illumination and displays 4 lines, each with 20 characters. The contrast has been factory set, but can be adjusted if required. See subsection Contrast (display) in the section Languages in the UNISAB instruction manual. In the display pressure levels, temperatures as well as all set points, warning and alarm limits can be read.

"STARTING" (lamp flashes) and "OPERATING" (lamp light steady ) can be seen in the bottom line of an operating picture. Pos. 3 Yellow lamp indicating whether the state of operation is automatic or manual. Yellow light = manual operation. Red lamp indicating warning or alarm. Slow flashes = warning Quick flashes = alarm A Compressor start at manual operation by pressing the key once. Works only if yellow lamp pos. 3 is lit. B Compressor stop at manual operation by pressing the key once. Works only if yellow lamp pos. 3 is lit. C A change between manual (yellow lamp on) and automatic (yellow lamp off) takes place by pressing the key once. Please note that if manual was selected from the CONTROL menu, it is not possible to change to automatic. See section Control Mode in the UNISAB instruction manual. D Key used to acknowledge alarms.

Pos. 4

Pos. 5

Front Panel
10 operating instructions.fm The UNISAB II front panel is divided into two sections: the control section, pos. 2-10, by means of which the compressor is controlled. the recording section, pos. 11-15, by means of which menu pictures are selected and values changed. Pos. 7 Pos. 6

Control Section
Pos. 2 Green lamp indicating whether the compressor is running. At start-up this lamp will flash until UNISAB II has received feedback from the motor starter. At the same time the text

Pos. 8

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10. Operating Instructions

Fig. 10.2

Front Panel of UNISAB II


10 9 8 7 3 4 2 5 6 1 11 13 12 14 15

I R O

Suct.temp. Dish.temp. Oil press. Ready

-25C 38C 4,3 bar 0%

S et

UNISAB II
Pos. 9 E Loading of capacity during manual operation. By pressing the E key once one capacity level is loaded on a reciprocating compressor with fixed rpm. On variable speed drive (VSD) compressors, the capacity is increased continuously by pressing the key. F Unloading of capacity during manual operation. By pressing the F key once one capacity level is unloaded on a reciprocating compressor with fixed rpm. On variable speed drive (VSD) compressors, the capacity is decreased continuously by pressing the key.

Recording Section
Pos. 11 G This key has several functions. When pressing the G key, a change will take place between Bar (PSI) and C/R (F/R) for saturated vapours when the display shows a suction or discharge pressure. Changing the set values can only be carried out by using the password shown on page 1 in the UNISAB instruction manual. As to the encoding of a password, see section Changing Set Values in the UNISAB instruction manual. Pos. 12 H Used for moving left in the menu system. Used for selecting pictures or a digit when changing a value. I Used for moving right in the menu system. Used for selecting pictures or a digit when changing a value.

Pos. 10

Pos. 13

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10. Operating Instructions

Pos. 14

J Used for moving upwards in a picture in order to point at a certain value, or when changing to a higher value. K Used for moving downwards in a picture in order to point at a certain value, or when changing to a lower value.

Menu Structure
The UNISAB II features a number of different pictures on compressor operation, set values, configuration, etc. and these pictures are built up in a menu system in which a certain picture can be selected by means of the arrow keys. See Instruction Manual for UNISAB II

Pos. 15

10 operating instructions.fm

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10. Operating Instructions

Preparations for Starting


Check the following points before starting the compressor for the first time after the installation. 1. Check that the oil goes up to the middle of the sight glass. If this is not the case, recharge with oil. Check that the safety equipment is set correctly. All safety functions are factory set. 3. This is the case for both analogue control and UNISAB II control. The heating element in the crankcase must be energized 6-8 hours before starting-up the compressor. Check that the valves are open according to Table 10.1.

2.

4.

Table 10.1
Pos no 1 2 3 4 5 6 7

Position during Operation


Qty 1 1 1 1 1 1 1 Designation Suction stop valve Discharge stop valve Air purge valve Oil charge valve Stop valve - after oil seperator Stop valve - receiver Stop valve - liquid line In operation position Open Open Closed Closed Open Open Open To be opened after start-up Remarks Must be opened by only a couple of turns.

Fig. 10.3

Principle Drawing - Position during Operation


3 1 2
To Conderser

4 Note! Other valves may occur. See Dimensions and Piping Diagram
Open Closed To Evaporator

5
From Condenser

6
Receiver

5.

Switch on the pilot voltage. Check that the emergency stop button, see Fig. 10.4, is in ON-position (the button must be in its outer-

most position). If the plant does not start, check that the fuses are intact. See Fig. 10.5.

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10. Operating Instructions

Fig. 10.4

Operator's Panel

Emergency stop button

Put the capacity regulation on minimum capacity. TSMC ia allowed to operate in a totally unloaded position for a maximum of 5 minutes. The operating temperature will otherwise be too high. Start the compressor on the control board or by means of A on UNISAB II (on compressors with analogue/digital control the start button is often mounted as an ON/OFF service cut-out on the compressor). Check suction and oil pressure. For compressors with variable speed drive (VSD), the oil pressure has to be adjusted at min. rpm and checked at max. rpm. Check if the oil is foaming in the sight glass. Check that the time relay keeps the solenoid valve in the oil return line shut for 20-30 minutes after the compressor has been started. Solenoid valve controlled oil return only. Open the suction stop valve slowly until it is completely open. Open the main shut-off valve in the liquid line. The compressor is now operating. Gradually increase the capacity to 100%. Do not leave the plant unattended the first 15 minutes after start-up.

Fig. 10.5 Drawing of Fuses and their Position

3 Amp

10 operating instructions.fm

U N IS AB II

Starting
Before starting up the plant, carefully read the section Preparations for Starting. Reset any alarms. When the plant is to be started for the first time, it is recommended to choose a manual starting-up procedure. Open the suction stop valve a couple of turns. Open all other valves except from the main shut-off valve in the liquid line. Start condenser cooling, brine pumps, ventilators at air coolers and maybe compressor cooling.

After start up, carry out the final regulation of the plant and set the plant to automatic operation.

Operating Mode UNISAB II


The compressor can be adjusted to different forms of operation. These are found in SETUP H CONTROL I.

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10. Operating Instructions

COMPRESSOR CTRL. MODE STOPPED

temperatures. These forms of regulation are found in CONFIG CONTROL ON. If you place the cursor on CONTROL ON and press G until the cursor moves to the right side of the picture, you can now select different types of regulation with the keysJ K. Among the following: SUCTION SIDE BRINE DISCH. SIDE HOT WATER EXT. COOL EXT. HEAT

When selecting this picture, the cursor will be in the top line. Press G and the cursor moves to the second line. It is now possible to select the desired form of operation with the keys J K. The possibilities are: STOPPED MANUAL AUTO REMOTE

STOPPED means that the compressor is blocked and thus cannot start. MANUAL means that the compressor only operates manually, i.e. you cannot change to another form on UNISAB II by means of the key C. However, the compressor can be started with A and stopped with the B key and capacity increased/decreased with the keys E F. AUTO means that the compressor runs in local automatic operation according to the form of regulation chosen (suction pressure, brine, etc). It is possible to change to MANUAL with the key C. REMOTE means that the compressor runs in remote regulation. It is chosen when a number of compressors are working together in a common MULTISAB regulating system. Regulators In UNISAB II it is possible to regulate the compressor according to different pressures and

These regulators have three set values in common: Set point (Sp), Neutral zone (Nz) and Proportional band (Pb). Set point Sp is the pressure or the temperature desired in the plant. Neutral zone Nz indicates how much the pressure or the temperature is allowed to fluctuate in relation to the Sp without the compressor changing its capacity. The set value of Nz positioned symmetrically around the set point (Sp+/- Nz). Proportional band Pb indicates how powerful the regulating signal to the compressor capacity regulation is going to be, depending on the difference between the desired value (Sp) and the actual value. In case the measured value is just outside the Nz, the regulating impulses will be very brief, whereas the regulating impulses will be very long if the measured value is outside the P-band. The Pband is positioned symmetrically around Sp outside the Nz.

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10. Operating Instructions

Fig. 10.6
2001.07.01
YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Tel.: +45 8736 7000 Fax: +45 8736 7705

"QUICK REFERENCE" LEAFLET FOR UNISAB II - One-stage Reciprocating Compressor

MAIN PICTURE Press H until the picture remains unchanged and this is your MAIN PICTURE.

Factorysetting

SUCT.PRESS DISCH.PRES MOTOR CURR

READY 2 SELECT THE "CONFIGURATION" MENU Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i Check whether UNISAB II is set correctly for the compressor. Press H until the Main picture appears.
CONTROL ON

XXXX XXXX XX X

XXXX

AUTO START YES


AUTO STOP COLD STORE

XXX XX XX

k 3 SELECT THE "TIMER SETUP" MENU Main picture - I suction - K setup - I control - Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i Check the set times in Timer setup Press H until the Main picture appears in the display. START START
STOP START

10 operating instructions.fm

XXX XXX XXX k XXX

START DELAY STOP DELAY

4 5

READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR C/R. Place cursor on suct. press or disch. pres and press "SET" (once). SELECT THE MENU FOR SUCTION PRESSURE REGULATION Main picture - I suction - I suct. press press "SET" for changing to C/R - - - - - - - - - - - - - - - - - - i Press H until the Main picture appears. HIGH ALARM HIGH WARNING LOW WARNING LOW ALARM k XXX XXX XXX XXX SETPOINT 1 SETPOINT 2 NEUTRAL ZONE PROP. BAND XXX XXX XXX XXX

CHANGING THE SET VALUES In order to be able to change a set value, a password must be encoded as described: Press "SET" for 2 seconds [Standard code number 1234]. Find the right password in the instruction manual With H I and J K the correct password is encoded Press "SET" and the password is kept open for 60 mins.

SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM) Main picture - I suction - I suct. press - I high alarm -- K low alarm Encode password (see pt. 6) - JK and HI changing of set values - SET for confirmation.

SELECT FUNCTION, f.inst. REGULATOR MODE Main picture - I suction - K setup - I control - K config. - I type - K control on Encode password (see pt. 6) - JK for selection of regulator - SET for confirmation.

SELECT COMPRESSOR CONTROL MODE Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2) - JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10

CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE Press -g to switch between manual - auto/remote The light diode above g lights up at manual control mode. It is always possible to change between manual and auto/remote - also during operation.

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10. Operating Instructions

11

MANUAL START (THE I-KEY): By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor. The ready-line changes to Prelubrication or Starting or Operating. (Text depending on compressor type) During the Starting period the green light diode flashes above the I-key. After feedback from the motor starter, the light diode changes to a steady light.

12 13

MANUAL STOP (THE 0-KEY) By pressing the "0"-key during operation, the compressor is stopped immediately. MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys) E regulates the compressor capacity upwards - F regulates the compressor capacity downwards. The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14

CONFIRMATION OF ALARMS (THE R-KEY) Slow flashes from the red light diode = The warning limit has been exceeded. Quick flashes from the red light diode = Alarm and compressor will stop. The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.

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10. Operating Instructions

Fig. 10.7
UNISAB II - Menu Tree One-stage Reciprocating Compressor I
Suction
SUCT.PRES. C/R SUCT.TEMP. C SUCT.SUPERH. C RUNNING 100%

PARAMETER SETTING
HIGH ALARM HIGH WARN. LOW WARN. LOW ALARM ACTUAL SP. SETPOINT 1 SETPOINT 2 NEUTRALZONE PROP.BAND C/R C/R C/R C/R C/R C/R C/R C/R C/R

Discharge
DISCH.PRES. C/R DISCH.TEMP. C DISC.SUPERH. C RUNNING 100%

Oil
SUCT.PRES. OIL PRES. OIL TEMP. RUNNING BAR BAR C 100%

Multisab state
START NO. SYSTEM NO. SYS.CONTROLLER

Motor
MOTOR CURR A CAPACITY % NOT USED % RUNNING 100%

All compressors
COMPR. # 01 MANUAL SYSTEM # 01 START # 01 100% RUNNING

Main picture
SUCT.PRES. DISCH.PRES. MOTOR CURR RUNNING C/R C/R A 100%

Main menu
SUCTION DISCHARGE OIL MOTOR BRINE ALARM WARNING SETUP

Brine
BRINE TEMP. SUCT.PRES EXT.INPUT RUNNING C C/R 100%

10 operating instructions.fm

Timers
START START STOP START START DELAY STOP DELAY SEC SEC SEC SEC

Alarms
NO ALARMS

Control
COMPR. CTRL. MODE MANUAL

Service-timers
ON TIME HOUR SINCE START

Warnings
NO WARNINGS

Multisab
MULTISAB MULTISAB STATE ALL COMPRESSORS PARALLEL CONTR.

Date-time
HOUR MIN SEC DAY

Dig. input Setup


CONTROL CALIBRATE MULTISAB TIMERS CONFIG DIAGNOSIS LANGUAGE

Timers
TIMERS TIMERS TIMER SETUP SERVICE TIMERS

D.INPUT D.INPUT D.INPUT D.INPUT

Dig. output
D.OUTPUT D.OUTPUT D.OUTPUT D.OUTPUT

Diagnosis
DIAGNOSIS INSPECT OLD ALARMS MISC.FUNCTIONS SOFTWARE VERSION

Analog. input
PRES. INP 1 PT 100 INP 1 EXT.

Calibrate
CALIBRATE PRESS TRANSDUCER BRINE TEMP. CAPACITY

4-20 MA input
4 MA 20 MA CAPACITY SETPOINT

Config.
TYPE REFRIGERANT CONTROL ON VOLUME RATIO

Auxiliary output
AUXILIARY OUTPUT ACTIVE WHEN AT MAX.CAP

Language

CONTRAST LANGUAGE

GB

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10. Operating Instructions

Fig. 10.8
2001.07.01
YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Tel.: +45 8736 7000 Fax: +45 8736 7705

"QUICK REFERENCE" LEAFLET FOR UNISAB II - Two-stage Reciprocating Compressor

MAIN PICTURE Press H until the picture remains unchanged and this is your MAIN PICTURE.

Factorysetting

SUCT.PRESS DISCH.PRES MOTOR CURR

READY 2 SELECT THE "CONFIGURATION" MENU Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i Check whether UNISAB II is set correctly for the compressor. Press H until the Main picture appears.
TYPE

XXXX XXXX XX X

XXXX

REFRIGERANT
CONTROL ON VOLUME RATIO

XXX XX XX

k 3 SELECT THE "TIMER SETUP" MENU Main picture - I suction - K setup - I control - Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i Check the set times in Timer setup Press H until the Main picture appears in the display. START START
STOP START

XXX XXX XXX XXX k

START DELAY STOP DELAY

4 5

READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR C/R. Place cursor on suct. press or disch. pres and press "SET" (once). SELECT THE MENU FOR SUCTION PRESSURE REGULATION Main picture - I suction - I suct. press press "SET" for changing to C/R - - - - - - - - - - - - - - - - - - i Press H until the Main picture appears. HIGH ALARM HIGH WARNING LOW WARNING LOW ALARM k XXX XXX XXX XXX SETPOINT 1 SETPOINT 2 NEUTRAL ZONE PROP. BAND XXX XXX XXX XXX

CHANGING THE SET VALUES In order to be able to change a set value, a password must be encoded as described: Press "SET" for 2 seconds [Standard code number 1234]. Find the right password in the instruction manual With H I and J K the correct password is encoded Press "SET" and the password is kept open for 60 mins.

SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM) Main picture - I suction - I suct. press - I high alarm -- K low alarm Encode password (see pt. 6) - JK and HI changing of set values - SET for confirmation.

SELECT FUNCTION, f.inst. REGULATOR MODE Main picture - I suction side- K setup - I control - K config. - I type - K control on Encode password (see pt. 6) - JK for selection of regulator - SET for confirmation.

SELECT COMPRESSOR CONTROL MODE Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2) - JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.

10

CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE Press - g to switch between manual - auto/remote The light diode above g lights up at manual control mode. It is always possible to change between manual and auto/remote - also during operation.

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10. Operating Instructions

11

MANUAL START (THE I-KEY): By READY in the main picture or in any other monitoring picture: Press "I" to start the compressor. The ready-line changes to Starting or Operating. ) During the Starting period the green light diode flashes above the I-key. After feedback from the motor starter, the light diode changes to a steady light.

12 13

MANUAL STOP (THE 0-KEY) By pressing the "0"-key during operation, the compressor is stopped immediately. MANUAL LOADING/UNLOADING OF CAPACITY (the E F keys) E regulates the compressor capacity upwards - F regulates the compressor capacity downwards. The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14

CONFIRMATION OF ALARMS (THE R-KEY) Slow flashes from the red light diode = The warning limit has been exceeded. Quick flashes from the red light diode = Alarm and compressor will stop. The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.

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10. Operating Instructions

Fig. 10.9
UNISAB II - Menu Tree Two-stage Reciprocating Compressor I
Suction
SUCT.PRES. C/R SUCT.TEMP. C SUCT.SUPERH. C RUNNING 100%

PARAMETER SETTING
HIGH ALARM HIGH WARN. LOW WARN. LOW ALARM ACTUAL SP. SETPOINT 1 SETPOINT 2 NEUTRALZONE PROP.BAND C/R C/R C/R C/R C/R C/R C/R C/R C/R

Discharge
DISCH.PRES. C/R DISCH.TEMP. C DISC.SUPERH. C RUNNING 100%

Oil
SUCT.PRES. OIL PRES. OIL TEMP. RUNNING BAR BAR C 100%

Multisab state
START NO. SYSTEM NO. SYS.CONTROLLER

Motor
MOTOR CURR A CAPACITY % NOT USED % RUNNING 100%

All compressors
COMPR. # 01 MANUAL SYSTEM # 01 START # 01 100% RUNNING

Main picture
SUCT.PRES. DISCH.PRES. MOTOR CURR RUNNING C/R C/R A 100%

Main menu
SUCTION DISCHARGE OIL MOTOR BRINE ALARM WARNING SETUP

Intermed.
INTERM.PRES C/R INTERM.TEMP C/R EXT.INPUT RUNNING 100%

Timers
START START STOP START START DELAY STOP DELAY SEC SEC SEC SEC

Alarms
NO ALARMS

Control
COMPR. CTRL. MODE MANUAL

Service-timers
ON TIME HOUR SINCE START

Warnings
NO WARNINGS

Multisab
MULTISAB MULTISAB STATE ALL COMPRESSORS PARALLEL CONTR.

Date-time
HOUR MIN SEC DAY

Dig. input Setup


CONTROL CALIBRATE MULTISAB TIMERS CONFIG DIAGNOSIS LANGUAGE

Timers
TIMERS TIMERS TIMER SETUP SERVICE TIMERS

D.INPUT D.INPUT D.INPUT D.INPUT

Dig. output
D.OUTPUT D.OUTPUT D.OUTPUT D.OUTPUT

Diagnosis
DIAGNOSIS INSPECT OLD ALARMS MISC.FUNCTIONS SOFTWARE VERSION

Analog. input
PRES. INP 1 PT 100 INP 1 EXT.

Calibrate
CALIBRATE PRESS TRANSDUCER BRINE TEMP. CAPACITY

4-20 MA input
4 MA 20 MA SUCT.PRES

Config.
TYPE REFRIGERANT CONTROL ON VOLUME RATIO

Auxiliary output
AUXILIARY OUTPUT ACTIVE WHEN AT MAX.CAP

Language

CONTRAST LANGUAGE

GB

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10. Operating Instructions

Checks during Operation


When the plant has been set for normal operating conditions, an inspection of the plant must be carried out. Check for leaks and vibrations in the system, noise from valves, etc. Particularly variable speed drive (VSD) compressors must be checked for vibrations due to natural frequency. Rpm resulting in vibrations must be locked out in the VSD controller. Check that oil pressure, suction and condensing pressure is within the permissible working range for the compressor.

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14. Transport Instructions

14. Transport Instructions


The purpose of this document is to describe: The dangers which may occur when the transport instructions and safety precautions are not observed. How to assemble and transport this equipment in a safe way. party nor be used for any unauthorised purpose. Contravention will be prosecuted.

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

This document is primarily intended for transport supervisors, authorities and personnel who are involved in loading, unloading and transporting the equipment. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third

Safety Precautions

WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this document, always read the safety precautions belonging to this equipment before transport. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

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Transport Data
Weight and Dimensions When dispatched, the unit is placed on a wooden frame and covered by plastic film. The wooden frame, which is adjusted to the size of the unit, is made so that the unit can be lifted with a forklift truck.

Table 14.1
Compressor Type SMC 104S-L SMC 106S-L SMC 108S-L SMC 112S-L SMC 116S-L SMC 104E SMC 106E SMC 108E SMC 112E SMC 116E TSMC 108S-L TSMC 116S-L TSMC 108S-L TSMC 116S-L Weight Kg 580 675 740 1250 1350 600 700 770 1300 1400 775 1400 800 1450 lb 1279 1488 1631 2756 2976 1323 1543 1698 2866 3086 1709 3086 1764 3197

The weight is exclusive electric motor

Table 14.2
Compressor type SMC 104 SMC 106 SMC 108 SMC 112 SMC 116 TSMC 108 TSMC 108 TSMC 116 TSMC 116

Weight of Compressor Units


Direct driven Kg 830 925 990 1660 1400 1060 1400 1900 2350 lb 1830 2039 2183 3660 3086 2337 3086 4189 5181 Kg 880 970 1030 1820 1920 1130 1410 2080 2530 Belt driven lb 1940 2138 2271 4012 4233 2491 3109 4586 5578 Excl. intermediate cooler Incl. intermediate cooler Excl. intermediate cooler Incl. intermediate cooler Remarks

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Table 14.3

Weight of Electric Motors


Motor Type Schorch IP 23 kg lb 419 462 529 584 783 1003 1058 1378 1499 1929 2083 2315 3946 4619 kg 102 173 188 235 309 340 445 570 630 900 940 1200 1500 1600 1750 (LA)1900 (LB)2150 IP 54 lb 225 381 414 518 681 750 981 1257 1389 1984 2072 2646 3307 3527 3858 (LA)1900 (LB)2150 kg 80 98 128 165 190 240 335 360 460 515 730 830 PLS lb 176 216 282 364 419 529 739 794 1014 1135 1609 1830 kg 78 100 110 170 205 235 340 445 490 720 785 Leroy Somer LS lb 172 220 243 375 452 518 750 981 1080 1587 1731 kg 120 135 184 260 290 388 395 475 565 850 1000 1050 FLS lb 265 298 406 573 639 855 871 1047 1246 1874 2205 2315

Sizes

14 transport instructions.fm

IEC 160L IEC 180M IEC 180L IEC 200M IEC 200L IEC 225S IEC 225M IEC 250S IEC 250M IEC 280S IEC 280M IEC 315S IEC 315M IEC 315L IEC 355S IEC 355M IEC 355L IEC 355L

190 210 240 265 355 455 480 625 680 875 945 1050 1790 2095

855

1885 1510 1550 3329 3417

Personnel Requirements
The personnel who are to handle the unit during loading, transport and unloading must have taken the necessary courses in the operation of cranes and forklift trucks.

Fig. 14.1

Loading Instructions
Lift the packed unit with a forklift truck. As a minimum the lifting capacity of the truck must correspond to the weight of the unit + the weight of the electric motor + an extra 100 kg for packing. If unpacked, the unit can be lifted with a crane. The unit must be lifted in the lifting eyes on the unit. Never lift in the lifting eyes of the compressor or the motor separately.

As a minimum the lifting capacity of the crane and the loading capacity of the chains, straps, lifting eyes and shackles must correspond to the weight of the unit + the weight of the electric motor + an extra 100 kg for packing.

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Preparations before Lifting


Before lifting the unit, make sure that straps/chains are properly secured to lifting eyes/shackles and that the lifting equipment is in good condition.

Unloading Instructions
The same rules apply as when loading the unit. See therefore Loading Instructions. Unpacking and Inspecting the Unit See Section 7, Installation Instructions. Moving the Equipment to Mounting Site after Unloading See Section 7, Installation Instructions.

Loading
Take great care when loading the unit so that it is not damaged. Note in particular that the instrumentation of the unit is very vulnerable to impacts.

Storage
On delivery the compressor units are charged with a protective gas (N2) with an overpressure of 0.2 bar to prevent moisture from entering the compressor. If the equipment is to be stored for a long time, the compressor should be equipped with a service manometer on the evacuation valve so that the pressure can be checked. If the pressure falls below 0.1 bar, recharge with nitrogen (N2). Place the unit on a level foundation and cover it so that it is protected against dust and dirt. The unit must not be stored with other objects which give off acidic vapours or the like as this can have a corrosive effect on the unit. It is moreover required that the store room is dry and frost-free. When stored, the unit must be inspected at regular intervals. Every two weeks the compressor and motor must be rotated 8-10 turns to prevent the oil in the bearings from drying. As far as the motor is concerned, check the lubricating nipples and lubricate them if necessary.

Transport Instructions

WDanger!
Risk of injury to personnel and damage to equipment! YORK Refrigeration does not assume responsibility for injury to personnel or damage to equipment caused by the use of transport methods which are not recommended in this document or stated in a separate agreement between a transport company and YORK Refrigeration. Transport Regulations It is the transport company's responsibility that all regulations pertaining to the transport are observed. It is moreover the transport company's responsibility that the unit or parts of the unit are properly secured and that they do not shift during the transport and thus get damaged.

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15. Commissioning Instructions

15. Commissioning Instructions


The purpose of this document is to describe: The dangers which may occur when the commissioning instructions and safety precautions are not observed. How to start-up this equipment in a safe way. How to prepare a safe and effective start-up. party nor be used for any unauthorised purpose. Contravention will be prosecuted.

WDanger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

This document is primarily intended for inspectors and supervisors. This document was produced by: 15 commissioning instructions.fm YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third

Safety Precautions

WDanger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in this document, always read the safety precautions belonging to this equipment before start. Failure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment.

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15. Commissioning Instructions

Preparations for Commissioning Final Check of Installation


Before the plant is put into operation, the installation must be checked one last time, see Section 7, Installation Instructions - Final Check of the Installation.

Preparations on the Mounting Site Final Check of the Plant


The check includes an examination of all parts of the plant and all the connections to the compressor. Check in particular that the piping connections are made as indicated in the installation drawings. all electrical connections have been checked. the unit and the plant have been pressure tested. the coupling between motor and compressor are set up as indicated in Section 7, Installation Instructions. the insulation has been carried out correctly. the paint is in order, the screens have been mounted correctly, etc.

Personnel Requirements
The personnel who are going to start up the plant must be well-qualified and have a thorough knowledge of refrigeration technique. It is moreover necessary that the personnel know the refrigeration plant and its construction and mode of operation. The instructions in this manual must be read before start-up. YORK Refrigeration offers courses which deal with operation of and service on the unit in question. It is recommended that both the supervisor and the operator take these courses.

Training
It must be made sure that all personnel have been trained so that the requirements listed under Personnel Requirements above are complied with.

Commissioning Instructions Preparations before the First Start-up


Before start-up, go through the following points: Section 10, Operating Instructions Preparations for Starting. UNISAB II's Starting-up Manual - Before Connecting the Voltage.

Documentation
Besides this manual the personnel should be in possession of the following documentation material before putting the plant into operation: Operating Manual Starting-up Manual and Instruction Manual for UNISAB II Certificates regarding the reciprocating compressor unit Installation drawings and functional descriptions for the plant

Go through the following point by point: Press the Emergency Stop button and connect voltage. Carry out configuration and setting as well as setting of alarms and warnings as described in Before Connecting Voltage in the Starting-up Manual for UNISAB II. Check that set values and alarm values correspond to the operating conditions of

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15. Commissioning Instructions

the plant. However, the values must not exceed the limits in the table of set/alarm values, see Section 9, Settings. Carry out calibration of pressure transducers as described in Calibration in the Starting-up Manual for UNISAB II. Pressure transducers must be calibrated at atmospheric pressure. The easiest way to do this is to dismount the transducers.

Check that the prescribed refrigerant corresponds to the specification on the compressor name plate. Charge the prescribed refrigerant. After charging the refrigerant, check all connections and valves for leaks by means of a leak detector. Start-up The plant can now be put into operation, See Section 10, Operating Instructions - Starting. After five hours of operation the alignment between motor and compressor must be checked again while the compressor is still warm. If the compressor is belt driven, check the belt tension. Before letting the plant start to work, activate the emergency stop and dismount the main fuses to ensure that the motor does not start unintentionally. Important! Note the procedures for reducing the evaporating pressure.

WDanger!
Inadequate or erroneous setting of pressure transducers may result in compressor breakdown or personal injury.

15 commissioning instructions.fm

Evacuation and Charging of Refrigerant


Check that the plant is evacuated to a pressure lower than 5 mm Hg. Pressure testing and evacuation of the plant is described in detail in Section 7, Installation Instructions.

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15. Commissioning Instructions

Checks to be Performed after Start-up


Check List Are settings and configuration correct? Have alarm and warning limits been set correctly? Have pressure transducers been calibrated? Is the direction of rotation of the motor correct? Has the coupling been aligned correctly? Have the safety valves been adjusted correctly? Has the plant been evacuated and dried before charging of refrigerant? Does the plant contain enough oil? Have valves been set correctly? Is the capacity regulation correct? Free passage for cooling water/refrigerant to e.g. oil cooler? Is the plant leak-proof?

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16. Compliance Instructions

16. Compliance Instructions


The purpose of this document is to describe: The norms and standards which this equipment complies with. How this equipment complies with the norms and standards. contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted.

Conformity with EU Regulations


According to current EU regulations, the manufacturer is under an obligation to document that the product complies with the EU Directive for Machines. This is done by completing a Declaration of Manufacturer, which contains the principal information about the product in question. The Directive for Machines does not apply to countries outside the EU. Example of a Declaration of Manufacturer, see Fig. 16.1.

This document is primarily intended for commissioning engineers, inspecting bodies and authorities. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark 16 compliance instructions.fm Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the

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Fig. 16.1 Declaration of Manufacturer With reference to EEC's Directive for machines 89/392 EEC as amended by 91/368/EEC - 93/44/EEC. Annex II B for machines to be incorporated. Manufacturer: YORK Refrigeration Operations Europe Chr. X's Vej 201 DK-8270 Hoejbjerg Tel.: +45 87367000 - Fax: +45 87367005

hereby declare that the below-mentioned product: Type:_____________________________ Compressor No:____________________ YORK Serial No:____________________ Year:_____________________________ Customer No:______________________ is constructed and manufactured in conformity with the above-mentioned EEC Directive. The product, which is covered by this declaration, may only be used when assembled with or incorporated into another machine/unit and thus in conformity with all relevant provisions. The following harmonised standards have been applied: DS/EN 292 DS/EN 294 DS/EN 418 Machine safety - Fundamental concepts Machine safety - Dangerous areas and safety distances Machine safety - Emergency functions

Besides in case of machines with electric equipment: Low-voltage switch gear and control gear assemblies EN 60 439-1 Type-tested and partially type-tested assemblies. Electrical equipment of industrial machines. EN 60 204-1 Operational instruction will be supplied. Complete technical documentation has been prepared Place and Date: Name and signature Agent/dealer stamp ____________________________ ____________________________

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17. Certificates

17. Certificates
The purpose of this document is to give an overall view of all certificates belonging to screw compressors. This document is mainly intended for inspecting bodies and authorities. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted. The compressors are made according to the basic specifications for the individual compressor type. The products comply with current legislation with regard to pressure and material testing. If the product is to be delivered with certificate, the certificate must be ordered when placing the order. It will not be possible to make a separate certificate for the compressor at a later time.

Approvals
Compressor Units Are designed to comply with common legislation in the EC-countries and former EFTA member states. The technical design complies with the requirements in the directives, most importantly the "Pressure Equipment Directive" (PED). Can also be delivered in a design according with the rules of the following classification societies: Lloyd's Register of Shipping Det Norske Veritas Germanischer Lloyd On request, compressor units can be designed to fulfil the standards of other countries and classification societies than the ones mentioned above

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20. Final Disposal

20. Final Disposal


The purpose of this document is to describe how to safely dispose of this equipment or part of it. This document is primarily intended for the de-commissioning engineers and authorities. This document was produced by: YORK Refrigeration Chr. Xs Vej 201 DK-8270 Hoejbjerg Denmark Copyright 2003 YORK Refrigeration This document must not be copied without the written permission of YORK Refrigeration and the contents hereof must not be imparted to a third party nor be used for any unauthorised purpose. Contravention will be prosecuted. Before dismantling the plant, refrigerant and oil must be drained into containers intended for the purpose. Disconnect all electrical connections to the unit. Remove fuses in the main switchboard. During the dismantling process, the individual machine parts and components must be sorted so that disposal can take place in an efficient way.

WDanger!
Take great care if using cutting tools, e.g. angle grinder or flame cutter, during the dismantling process as pipes or the like will contain oil residue which may ignite. Refrigerant residue does also involve a great risk as HFC and HCFC refrigerants will develop toxic gasses when heated. Make sure that there are no air traps as heating will result in a pressure rise.

20 final disposal.fm

General Disposal of Machine Parts Safety Precautions


When dismantling the plant, it is important to sort the parts to be disposed of. Compressor, frame, containers, etc. belonging to the category of iron and metal scrap must be delivered to an approved scrap dealer complying with the prevailing rules and regulations of the individual country.

WDanger!
Before dismantling the plant, read Section 3, Safety Precautions carefully. Failure to do so may result in personal injury or even death. Dismantling of a cooling unit which is to be scrapped must be carried out in a safe way. Authorized refrigeration personnel must participate in the first part of the dismantling process as fundamental knowledge of refrigerating systems and the risks involved is required.

Disposal of Oil and Refrigerant


Oil and refrigerant must be delivered for destruction or regeneration at a receiving station for hazardous waste, including used oil filters. The receiving station must comply with the prevailing rules and regulations of the individual country.

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20. Final Disposal

Disposal of Electrical Components


Electrical and electronic products, e.g. wiring, panels, hardware, etc., must be delivered to a receiving station approved to handle electronic waste. The receiving station must comply with the prevailing rules and regulations of the individual country.

Disposal of Batteries
Used batteries from e.g. the backup of the computer control must be delivered for destruction at a receiving station. The receiving station must comply with the prevailing rules and regulations of the individual country.

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Appendix - SMC/TSMC 100


This section includes data sheets and instructions concerning the components and the tables of torque moments. 1. 2. 3. 4. List of torque moments, 4 pages. Danfoss pressure transducer type AKS, 9 pages. Tempress temperature sensor P2208, 3 pages. Valves Danvalve installation instructions SCV 40-200, 2 pages. PM valves, 10 pages Pilot valve, 3 pages 5. Solenoid valve for oil return Instruction EVRB-NC, 1 page 6. Danfoss automatic Pressure cut-outs type KP, 4 pages Pressure cut-outs type MP, 7 pages Thermostats type KP, 5 pages Thermostatic expansion valves, 9 pages Thermostatic injection valves, 5 pages

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Fig. 21.1

1 Z D a B F C X 2

Table 21.1
Compressor AMR type of coupling Nominal Distance C F Torque moment Max. variation measured with a feeler gauge at a 180 turning of the coupling D Pos. 1 Horizontal max. mm 0,2 0,2 Vertical min./max. mm 0,1/0,3 0,1/0,3 Pos. 2 max. mm 0,2 0,2

mm HPC/SMC 104-108 SMC 112-116 312 S 350 S 103,5 114,5

mm 25 27

Nm 147 147

Nm 55 128

Nm 44 44

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Torque Moments for Screws and Bolts

Metric thread (ISO 8.8)


M Kpm ft.lbf. Nm 4 0.28 2.1 2.7 5 0.53 3.9 5.2 6 0.94 6.8 9.2 8 2.2 16 22 10 4.1 30 40 12 7.0 50 69 14 11 80 108 16 15 110 147 18 23 170 225 20 30 220 295 22 38 270 375 24 52 370 510 27 68 490 670

Metric thread (ISO 12.9)


M Kpm ft.lbf. Nm 4 0.42 3.0 4.1 5 0.78 5.7 7.6 6 1.4 10 14 8 3.2 23 31 10 6.1 44 60 12 10 75 98 14 16 120 157 16 23 160 225 18 34 240 335 20 44 320 430 22 55 400 540 24 76 550 745 27 100 720 980

21 appendices.fm

Connecting rods with UNF thread


HPO/CMO UNF Kpm ft.lbf.. Nm 5/16 2.1 15 20 HPC/SMC 100 3/8 4.4 32 43 SMC 180 5/8 17 130 167

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Sundry Clearances and Check Dimensions


Bearing clearance
CMO 1 CMP 1 TCMO 1 CMO 4 Main bearings Connecting rod bearings Piston pin bearings Parallel to piston pin Al right angles to piston pin manufactured max. manufactured max. manufactured max. manufactured max. manufactured max. 0.08 0.20 0.08 0.15 0.04 0.10 0.18 0.11 0.30 CMO 2 TCMO 2 HPO 0.08 0.20 0.08 0.15 0.04 0.10 0.18 0.11 0.30 0.08 0.20 0.08 0.15 0.04 0.10 0.20 0.11 0.30 SMC 65 TSMC 65 SMC 100 TSMC 100 4-10 cyl. HPC 0.08 0.20 0.10 0.20 0.04 0.10 0.20 0.15 0.40 SMC 100 TSMC 100 12-16 cyl. 0.08 0.20 0.10 0.20 0.04 0.10 0.20 0.15 0.40 SMC 180 TSMC 180 Mk 1 & Mk 2 0.14 0.35 0.14 0.30 0.09 0.20 0.25 0.35 0.90

If the maximum value has been exceeded, replace the parts.

Crankshaft end-play
min. max. 0.30 0.55 0.30 0.55 0.40 0.55 0.40 0.64 0.75 1.00 0.95 1.20

The end-play can be adjusted by means of the gasket under the bearing cover. The gasket is available in the following thicknesses: 0.3, 0.5, 0.75, 1.0, 1.3, 1.5, 1.75 and 2.0 mm.

Piston ring gap


min. max. 0.25 1.00 0.25 1.00 0.25 1.00 0.33 1.30 0.33 1.30 0.66 1.50

The piston ring gap must be measured with the ring placed in the cylinder liner.

Dimensions of crankshaft bearing journal


Main bearing journals New Connecting rod bearing journals Intermediate journals -0.06 -0.09 -0.025 -0.040 -0.06 -0.09 -0.025 -0.040 -0.06 -0.09 0 -0.02 -0.07 -0.09 0 -0.02 55 50 -0.06 -0.09 -0.025 -0.040 60 55 -0.06 -0.09 -0.030 -0.049 55 55 -0.06 -0.09 0 -0.02 80 80 -0.07 -0.09 0 -0.02 80 80 80 54.5 49.5 59.5 54.5 54.5 54.5 79.5 79.5 79.5 79.5 79.5 -0.07 -0.09 0 -0.02 -0.010 -0.029 -0.07 -0.09 0 -0.02 -0.010 -0.029 134 134 -0.11 -0.14 -0.015 -0.040 135 135 -0.11 -0.14 -0.015 -0.040

Piston Ground down

Main bearing journals Connecting rod bearing journals Intermediate journals

Bushing and bearing valves can be supplied for all above journals.

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Index
A Accidents with Ammonia ....................................................................................... 23 Accidents with HFC/HCFC .................................................................................... 24 Achieving Parallel Shafts in Horizontal Plane .................................................................................................. 223 Air-Cooled Top and Side Covers ........................................................................... 96 Air-Cooled Top and Side Covers and Refrigerant-Cooled Oil Cooler ................... 96 Air-Cooled Top Covers and Water Cooled Side Covers ....................................... 96 Alignment of Compressor on Base Frame .......................................................................... 218 Motor on Base Frame .................................................................................... 218 Alignment of Unit against Foundation .................................................................. 216 AMR ..................................................................................................................... 151 Analogue Reading ................................................................................................. 72 anti-clockwise ...................................................................................................... 140 Area of Application ................................................................................................ 33 Areas of Application ............................................................................................... 29

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Boring of Hub ....................................................................................................... 149 Brine ...................................................................................................................... 28 By-pass system ..................................................................................................... 45 By-pass Valve SMC ................................................................................................................. 35

Capacity Regulation .............................................................................................. 58 Capacity Regulation of Thermo Pump ................................................................... 92 Capacity Stages .................................................................................................... 63 Caution Texts Marked with Caution .............................................................................. 17 Charging of oil ..................................................................................................... 230 Charging the Compressor with Oil ....................................................................... 176 Check of the Installation ...................................................................................... 231 Checks during Operation ..................................................................................... 259 Checks to be Performed after Start-up ................................................................ 268 Choice of Electric Motor ...................................................................................... 141 Coils for Solenoid Valves ..................................................................................... 113 Commissioning Checks to be Performed after Start-up .......................................................... 268 Preparations ................................................................................................... 266 Preparations before the First Start-Up ........................................................... 266 Commissioning Instructions ................................................................................. 265 Compliance Instructions ...................................................................................... 269 Components ........................................................................................................ 233 Compressor Accessories ....................................................................................... 97

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Compressor Block TSMC ...............................................................................................................43 Compressor Name Plate .......................................................................................12 Compressor Shaft ................................................................................................149 Compressor Units ..................................................................................................71 Connecting Rod SMC .................................................................................................................34 Connection Data ..................................................................................................100 Connections on SMC Long block ......................................................................................................105 Control Section ....................................................................................................247 Conversion of TSMC Mk2 to SMC ........................................................................46 Cooling Media ........................................................................................................28 Cooling of Compressor and Oil SMC .................................................................................................................41 Cooling system Booster Compressor ........................................................................................82 Pressure Loss ..................................................................................................88 R22 ..................................................................................................................81 R717 ................................................................................................................81 Thermo pump .............................................................................................89, 90 Water flow ........................................................................................................87 Water pressure ................................................................................................87 Water temp. .....................................................................................................87 Cooling Systems ....................................................................................................81 Cooling with Thermo Pump ...................................................................................89 Correct Centre .....................................................................................................224 Coupling AMR ...............................................................................................................151 Coupling Types ....................................................................................................149 Crankshaft SMC .................................................................................................................36

Danger Texts Marked with Danger ...............................................................................17 Description .............................................................................................................78 Additional unloading .........................................................................................64 Analogue Reading ...........................................................................................72 By-pass system ................................................................................................45 Capacity Regulation .........................................................................................58 Solenoid Valves ..........................................................................................60 Capacity Stages ...............................................................................................63 Conversion of TSMC Mk2 to SMC ...................................................................46 Cooling of the Intermediate Gas ......................................................................45 Cooling system R22 .............................................................................................................81 R717 ...........................................................................................................81 Determining the Intermediate Pressure IP .......................................................79

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Discharge Pipe Thermostat KP98 .................................................................... 73 DVEA ............................................................................................................... 77 High Pressure Cut-out KP15 ............................................................................ 73 Intermediate Cooling TEAT .......................................................................................................... 78 TEA-TEX .................................................................................................... 78 Intermediate Gas ............................................................................................. 77 Intermediate Pressure Cut-out KP5 ................................................................. 73 Low Pressure Cut-out KP15 ............................................................................ 73 Oil Differential Cut-out MP55 ........................................................................... 73 Oil Thermostat KP98 ........................................................................................ 73 Regulation of Intermediate Pressure IP ........................................................... 79 SMC By-pass Valve ............................................................................................ 35 Connecting Rod .......................................................................................... 34 Cooling of Compressor and Oil .................................................................. 41 Crankshaft .................................................................................................. 36 Cylinder liners ............................................................................................. 33 Discharge Valve ......................................................................................... 34 Draining valve ............................................................................................. 40 Evacuating Valve ........................................................................................ 40 Filter bag .................................................................................................... 34 Heating Rod ............................................................................................... 40 Instrumentation ........................................................................................... 41 Oil Filter ...................................................................................................... 37 Oil Level Glass ........................................................................................... 40 Oil Pressure Regulating Valve ................................................................... 37 Oil Pump ..................................................................................................... 37 Pistons ........................................................................................................ 33 Safety spring .............................................................................................. 34 Shaft Seal ................................................................................................... 38 Stop Valves ................................................................................................ 41 Suction Filter .............................................................................................. 34 Suction Valve ............................................................................................. 34 Special unloading 104 ...................................................................................... 65 Standard unloading .......................................................................................... 62 Start Unloading ................................................................................................ 60 Suction Filters .................................................................................................. 45 TEA .................................................................................................................. 78 TEAT ................................................................................................................ 78 Total Unloading ................................................................................................ 63 TSMC Compressor Block ...................................................................................... 43 Intermediate pressure ................................................................................ 44 Needle bearing ........................................................................................... 44 Piston Pin Bearing ...................................................................................... 44 Water Quality ................................................................................................... 88 Description of Compressor Types ......................................................................... 31 Description of Pumping Cycle ............................................................................... 92

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Determining the Intermediate Pressure IP ............................................................79 Dimension Sketches ....................................................................................100, 120 Direction of Rotation ............................................................................................140 Electric Motor .................................................................................................147 Direction of Rotation of Electric Motor .................................................................147 Discharge GasTemperatures ..............................................................................242 Discharge Pipe Thermostat KP98 .........................................................................73 Discharge Pressure,PT2 .....................................................................................111 Discharge Valve ....................................................................................................34 Display .................................................................................................................247 Unisab II .........................................................................................................247 DVEA .....................................................................................................................77

Electric Motor .......................................................................................................141 Direction of Rotation ......................................................................................147 Electrical Connections .........................................................................................110 Electricity Supply .................................................................................................226 Emergency Stop ....................................................................................................16 Ensuring Liquid to the Thermo Pump ....................................................................94 Evacuating Valve SMC .................................................................................................................40 Explosion-proof ......................................................................................................97 Explosion-proof heating .........................................................................................97 Explosion-proof solenoid valves ............................................................................97 Extended set of tools .............................................................................................97

Filter bag SMC .................................................................................................................34 Final Check of the Installation .............................................................................231 Final Disposal ......................................................................................................273 First aid Accidents with Ammonia ..................................................................................23 Accidents with HFC/HCFC ...............................................................................24 Foundation ...........................................................................................................159 Mounting Directly on Foundation ...................................................................160 Front Panel ..........................................................................................................247 Front Panel of UNISAB II .....................................................................................248 Fuses ...................................................................................................................251

Handling of Compressor and Unit .......................................................................148 Heating Element ..................................................................................................113 Heating Rod SMC .................................................................................................................40 High voltage ...........................................................................................................22 Hot and Cold Surfaces ........................................................................................244

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Hub Boring of Hub ................................................................................................. 149

Installation and Relocation Safety ......................................................................... 21 Installation Instructions ....................................................................................................................... 213 Instrumentation ...................................................................................................... 72 SMC ................................................................................................................. 41 Intermediate Cooler Type DVEA ........................................................................... 77 Intermediate Cooling Liquid Injection ................................................................................................. 78 TEAT ................................................................................................................ 78 TEA-TEX .......................................................................................................... 78 Intermediate Gas .............................................................................................45, 77 Intermediate pressure TSMC ............................................................................................................... 44 Intermediate Pressure Cut-out KP5 ....................................................................... 73

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KP 15 ................................................................................................................... 245 KP 5 ..................................................................................................................... 245 KP 98 ................................................................................................................... 245 KP15 ...................................................................................................................... 73 KP5 ........................................................................................................................ 73 KP98 ...................................................................................................................... 73

Laying the Foundation ......................................................................................... 159 Lifting and Carrying Safety .................................................................................... 20 Lifting the compressor Block ............................................................................... 148 Lifting the compressor Unit .................................................................................. 148 Liquid Injection ....................................................................................................... 78 Loading Instructions ............................................................................................ 263 Long block ............................................................................................................. 31

Machine Room Planning ......................................................................................................... 124 Maintenance Safety ............................................................................................... 21 Manometers Description Manometers ............................................................................................... 74 Marine Installations .............................................................................................. 164 Max. Power Transmission ................................................................................... 155 Measured and Calculated temp. .......................................................................... 239 Menu Tree SMC ............................................................................................................... 255 TSMC ............................................................................................................. 258

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Moment of Inertia .................................................................................................146 Motor Dimension .................................................................................................141 Motor weight ........................................................................................................118 Mounting Directly on Foundation .........................................................................160 Mounting Directly on the Foundation ...................................................................218 Mounting of Vibration Dampers ...........................................................................161 Mounting on Vibration Dampers ..........................................................................217 MP 55 ..................................................................................................................245 MP55 .....................................................................................................................73

Needle bearing TSMC ...............................................................................................................44 Nitrogen charge .....................................................................................................71 Noise ...................................................................................................................166 Damping Acoustic Noise ................................................................................171 Reverberation Time .......................................................................................171 Normal set of tools .................................................................................................97 Nozzle size ............................................................................................................49

Oil Charging .................................................................................................176, 230 Oil Consumption ..................................................................................................177 Oil Cooling Settings ..........................................................................................................241 Oil Differential Cut-out MP55 .................................................................................73 Oil Draining Valve SMC .................................................................................................................40 Oil Filter SMC .................................................................................................................37 Oil Level Glass SMC .................................................................................................................40 Oil Pressure .........................................................................................................112 Oil Pressure Regulating Valve SMC .................................................................................................................37 Oil Pump SMC .................................................................................................................37 Oil Return ..............................................................................................................48 Coil for the solenoid valve ................................................................................49 Float Valve Controlled ......................................................................................51 Parallel Operation ............................................................................................51 Different Et ..................................................................................................55 Float valve ..................................................................................................53 Same Ct ......................................................................................................57 Same Et ......................................................................................................52 Oil return Nozzle size .......................................................................................................49 Solenoid Valve Controlled ................................................................................48 Oil Separators ......................................................................................................178

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Oil Thermostat KP98 ............................................................................................. 73 One-stage .............................................................................................................. 32 Opening the Cabinet ............................................................................................ 246 Operating Instructions ......................................................................................... 243 Operating Limits Diagrams .................................................................................. 125

Parallel Operation .................................................................................................. 51 Parallel Shafts ..................................................................................................... 223 Personal Safety ..................................................................................................... 19 Physical and Connection Data .............................................................................. 99 Piping Connections .............................................................................................. 225 Piston Pin Bearing TSMC ............................................................................................................... 44 Pistons SMC ................................................................................................................. 33 Planning the Machine Room ............................................................................... 124 Power Transmission ............................................................................................ 155 Preliminary Installation ........................................................................................ 223 Preparations for Starting ...................................................................................... 250 Pressure .............................................................................................................. 243 Pressure and Temperature Setting ..................................................................... 238 Pressure levels .................................................................................................... 175 Pressure Loss ........................................................................................................ 88 Pressure Testing ................................................................................................. 228 Pressure transmiters Discharge Pressure,PT2 ................................................................................ 111 Oil Pressure ................................................................................................... 112 Suctiaton Pressure,PT1 ................................................................................. 111 Pressure Transmitters AKS32-AKS2050 ........................................................................................... 111 PT1 ...................................................................................................................... 111 PT2 ...................................................................................................................... 111 PT3-PT1 .............................................................................................................. 112 Purging a Refrigeration Plant ................................................................................ 27

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Quick Reference One Stage ...................................................................................................... 253 SMC ............................................................................................................... 253 TSMC ............................................................................................................. 256

Refrigerants .....................................................................................................27, 28 Regulation of Intermediate Pressure IP ................................................................. 79

Safety at Servicing ................................................................................................. 16 Safety Instructions

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High voltage .....................................................................................................22 Installation and Relocation ...............................................................................21 Lifting and Carrying Safety ...............................................................................20 Maintenance Safety .........................................................................................21 Personal Safety ................................................................................................19 Set-Up and Operation ......................................................................................21 Tool Safety .......................................................................................................20 Work Area Safety .............................................................................................20 Safety Precautions ................................................................................................19 Settings ................................................................................................................237 Oil Cooling .....................................................................................................241 Unisab II .........................................................................................................239 Set-Up and Operation Safety ................................................................................21 Shaft Seal SMC .................................................................................................................38 Short blocks ...........................................................................................................31 Sign CAUTION .........................................................................................................14 Cold surfaces ...................................................................................................15 Dangerous noise level .....................................................................................15 Hazardous substance ......................................................................................15 High Voltage ....................................................................................................14 Internal overpressure .......................................................................................15 Internal Protection ............................................................................................15 Temperature of Tangible Surfaces ..................................................................15 Signs and Warnings ................................................................................................9 Signs in Instructions ..............................................................................................14 SMC Cylinder liners ..................................................................................................33 Designation ......................................................................................................31 Safety spring ....................................................................................................34 Type E ..............................................................................................................31 Type L ..............................................................................................................31 Type S ..............................................................................................................31 SMC/HPC 104 Special Unloading .........................................................................65 Sound Data How to check .................................................................................................170 Spare parts set ......................................................................................................97 Special unloading 104 ...........................................................................................65 Specification of Materials .....................................................................................174 Start Unloading ......................................................................................................60 Start up SMC/HPC 100 - HFC/HCFC - 25% load ........................................................145 Start up torque SMC/HPC 100 R717 25% load ...................................................144 Starting ........................................................................................................250, 251 Starting Torque ....................................................................................................143 Stop Valves SMC .................................................................................................................41 Structure of the Thermo Pump ..............................................................................90

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Suctiaton Pressure,PT1 ....................................................................................... 111 Suction Filter SMC ................................................................................................................. 34 Suction Filters ........................................................................................................ 45 Round holes ..................................................................................................... 45 Square holes .................................................................................................... 45 Suction Valve SMC ................................................................................................................. 34

TEA ........................................................................................................................ 78 Technical Data ..................................................................................................... 116 Technical Description ............................................................................................ 29 Temperature Sensors .......................................................................................... 112 Discharge Gas TT5 ........................................................................................ 112 Oil TT6 ........................................................................................................... 112 Suction Gas TT7 ............................................................................................ 112 Test Pressure ...................................................................................................... 175 Test pressure ....................................................................................................... 228 Test Pressure Levels ........................................................................................... 175 TEX ........................................................................................................................ 78 The compressor must NOT be used ..................................................................... 30 Thermo Pump Capacity Regulation ......................................................................................... 92 Thermo pump ........................................................................................................ 89 Description of the Pumping Cycle .................................................................... 92 Ensuring Liquid ................................................................................................ 94 Power Connection ............................................................................................ 95 Structure .......................................................................................................... 90 Thermodynamic Liquid Trap .................................................................................. 50 TLT Thermodynamic Liquid Trap .......................................................................... 50 Tool Safety ............................................................................................................ 20 Total Unloading ..................................................................................................... 63 Transport Data ............................................................................................................... 262 Instructions ..................................................................................................... 261 TT5 ...................................................................................................................... 112 TT6 ...................................................................................................................... 112 TT7 ...................................................................................................................... 112 TWA-Werte ............................................................................................................ 25 Two-stage .............................................................................................................. 32 Two-stage Compressors TSMC ............................................................................................................... 43 Type E ....................................................................................................................... 31 L ....................................................................................................................... 31 S ....................................................................................................................... 31 Types of Spare Parts Set ...................................................................................... 98

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UNISAB II ..............................................................................................................75 Operating Mode .............................................................................................251 Settings ..........................................................................................................239 Unisab II ..............................................................................................................246 Control Section ..............................................................................................247 Display ...........................................................................................................247 Front Panel ............................................................................................247, 248 Fuses .............................................................................................................251 Menu Tree SMC .............................................................................................255 Menu Tree TSMC ..........................................................................................258 Quick Reference ............................................................................................253 Quick Reference SMC ...................................................................................253 Quick Reference TSMC .................................................................................256 Starting ...........................................................................................................251 Unit Pipe System Name Plate ...............................................................................11

Valve Position during Operation ..........................................................................250 V-Belt Drive .........................................................................................................153 Construction ...................................................................................................157 Motor pulley ...................................................................................................158 V-Belts and Pulleys .............................................................................................154 Ventilation ............................................................................................................243 Vessel Name Plate ................................................................................................12 Vibration Dampers Mounting ........................................................................................................161 Vibration dampers .................................................................................................97 Vibration Data ......................................................................................................173

Warning Texts Marked with Warning .............................................................................17 Warnings in Instructions ........................................................................................17 Water flow ..............................................................................................................87 Water pressure ......................................................................................................87 Water Quality .........................................................................................................88 Water temp. ...........................................................................................................87 Weight of Electric Motors .............................................................................118, 263 Welding Nipples for ANSI ....................................................................................104 Welding Nipples for R-KB ....................................................................................103 Work Area Safety ..................................................................................................20

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